CONTRACT DOCUMENTS AND SPECIFICATIONSAGMA 6019E-89-Gear Motors Using Spur, Helical, Herringbone, Straight Bevel, or Spiral Bevel Gears 5. AGMA 6023-A88 Design Manual for Enclosed Epicyclic

CONTRACT DOCUMENTS AND

SPECIFICATIONS

FOR

Town of Flower Mound Wastewater Treatment Plant

Rehabilitation Phase IV - Solids Facility Improvements Part 1

BID # 2016-72

Volume II

June 2016

Prepared by:

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PUMP, PROGRESSIVE CAVITY F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 11\11060 PUMP, PROGRESSIVE CAVITY.DOCX

SECTION 11060 PUMP, PROGRESSIVE CAVITY

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Furnish, install, startup, and test two (2) progressive cavity pumps, complete and operable with pump base, appurtenances, controls and all other components required to meet the specified pumping conditions, as shown on the plans and specified herein.

B. Related Sections: 1. Section 03600 “Grout” for support base. 2. Division 13 – Instrumentation 3. Division 16 – Electrical

1.3 REFERENCES

A. References: Following is a list of standards, which might be referenced in this Section: 1. American Bearing Manufacturers Association (ABMA) 2. ASTM International (ASTM):

a. A36 – Standard Specification for Carbon Structural Steel b. A519 – Standard Specification for Seamless Carbon and Alloy Steel Mechanical

Tubing 3. American Gear Manufacturers Association (AGMA) 6010-E-88 Spur, Helical,

Herringbone, and Bevel Enclosed Drive 4. AGMA 6019-E-89 Gear Motors Using Spur, Helical, Herringbone, Straight Bevel, or

Spiral Bevel Gears 5. AGMA 6023-A88 Design Manual for Enclosed Epicyclic Gear Drives 6. National Electrical Manufacturer’s Association (NEMA): MG-1, Motors and Generators 7. National Fire Protection Association (NFPA): NFPA 70, National Electric Code

1.4 SYSTEM DESCRIPTION

A. Design Requirements: 1. Refer to the “Pump Data Sheet” at the end of this Section for details on the pump

design characteristics. 2. Orientation of the pumps shall comply with the Drawings. 3. All equipment, including controls and drives specified herein, shall be specifically

designed for pumping in application specified in “Pump Data Sheet” and the environment encountered in this installation. The environment will be moist and corrosive, exhibiting hydrogen sulfide and other corrosive gases encountered in municipal wastewater treatment plants.

4. The two belt feed pumps are inside the dewatering building. 5. Equipment shall be designed and capable of either continuous or intermittent operation.

The specifications and drawings cover certain required features of the equipment, but do not purport to cover all details entering into its design.

6. All equipment, supports, anchors and fasteners shall be of adequate strength to withstand loads associated with starting, turbulence, thrusts from liquid movement, thermal expansion and contraction and other loads encountered under normal operating conditions.

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7. Summary: a. Provide two (2) Belt Filter Press Feed Pumps, BFP-1 and BFP-2. b. Refer to P&IDs, Drawings, and Division 17 Sections regarding the control logic

and description for additional pump monitoring and control information as applicable.

1.5 PERFORMANCE REQUIREMENTS

A. Guaranteed Performance: Transfer the product at the operating conditions as listed in the Pump Data Sheet and as shown on the Pump Curve(s), if applicable.

B. Pumping Unit System: Comply with performance requirements specified, as determined by testing assemblies representing those indicated for this Project.

C. Specific Performance Requirements: Refer to attached Pump Data Sheet after End of Section.

D. The equipment, sizes, materials, and arrangements described in this specification section are based on recommendations by equipment manufacturers and shall be considered minimum limits of acceptability. The equipment manufacturer shall be responsible for design, arrangement, and performance of all equipment supplied under this section. Arrangements other than those shown on the plans shall be subject to the ENGINEER’s approval.

E. The dimensions and orientation of the piping and pumps are shown on the plans.

1.6 SUBMITTALS

A. Submittals shall be prepared in accordance with Division 1.

B. Product Data: Include construction details, material descriptions, dimensions of individual components and profiles, pump curves for rated capacities, operating characteristics, electrical characteristics, and any optional features and accessories.

C. Shop Drawings: Include plans, elevations, sections, details, and attachments specific to the project, bound neatly in a single package. The following information shall be included as a minimum: 1. Manufacturer and model number of equipment. 2. Detail equipment assemblies and indicate dimensions on layout drawings, weights,

loads, required clearances, method of field assembly, components, and location and size of each field connection.

3. Performance data curves showing head, capacity, horsepower demand, and pump efficiency over the entire operating ranges of the pump, from shutoff to maximum capacity. a. Indicate separately the head, capacity, horsepower demand, and overall

efficiency. 4. Wiring Diagrams: If applicable, for power, signal, and control wiring diagrams,

including terminals and numbers. 5. Complete motor nameplate data, as defined by NEMA, motor manufacturer, and

include any motor specifications. 6. Documentation demonstrating factory finish is equivalent to finish system specified in

this Section.

D. Informational Submittals: 1. Factory functional and performance test reports and logs. 2. Manufacturer’s Certification of Compliance. 3. Special shipping, storage and protection, and handling instructions. 4. Manufacturer’s instructions for installation. 5. Manufacturer’s Certificate of Proper Installation. 6. Qualification Data: For manufacturer and manufacturer’s representative.

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7. Suggested spare parts list to maintain the equipment in service for a period of two years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current pricing information.

8. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance.

9. Warranties and service agreements.

E. Operation and Maintenance Data: For each pumping system to include in operation and maintenance manuals. Provide in accordance with Section 01300 “Project Documentation”.

F. Control Panel Construction Requirements: Refer to Section 16486 “Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs)”, for the construction requirements of each Control Panel. All panels specified under this Section, shall be submitted as a part of each associated mechanical equipment submittal.

G. Partial or incomplete submittals may be returned by the ENGINEER without review.

H. All deviations from contract documents shall be submitted separately by CONTRACTOR as a Contract Modification Request.

I. Provide any other information necessary for the ENGINEER to determine compliance with the specifications.

1.7 QUALITY ASSURANCE

A. Manufacturer Qualifications: 1. All equipment shall be the product of a manufacturer having at least twenty (20) similar

system installations in the United States of the type proposed, each with a minimum of five (5) years of satisfactory service.

2. A list of similar installations shall be furnished with the shop drawing submittal, including names and telephone numbers of contacts.

B. Manufacturer’s Representative Qualifications: Manufacturer's authorized representative who is trained and approved for installation of units required for this Project.

C. Source Limitations: All equipment units of each type specified in this section shall be supplied by a single manufacturer. The manufacturer of the equipment specified herein shall be responsible for the satisfactory operation and the associated equipment listed herein.

D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

E. Manufacturer shall maintain a complete stock of spare parts commonly needed for the equipment specified at a location within the State of Texas, or spare parts shall be made available within 48 hours of notification.

F. All equipment shall have a 316 stainless steel manufacturer’s nameplate securely affixed in a conspicuous place on the equipment showing the ratings, serial number, model number, manufacturer and other pertinent nameplate data.

G. The equipment manufacturer shall furnish and be responsible for the complete system including pump and motor. Provide all pertinent information for pumps and motors to the electrical contractor and VFD supplier.

H. Manufacturer’s installation report is required prior to final acceptance.

1.8 SOURCE QUALITY CONTROL

A. Factory Tests and Adjustments: Test all pumping units and control panels to be furnished. 1. Include test data sheets, curve test results, performance test logs, certified by a factory

test engineer.

B. Performance Test:

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1. Perform on each pump in accordance with Hydraulic Institute Standards. 2. Tests shall be sufficient to determine the curves of head, input horsepower, and

efficiency relative to capacity throughout the specified flow range. A minimum of three points shall be taken for each test.

3. At least one point shall be obtained as near as possible to each specified condition. 4. Results of the performance test shall be certified by a Registered Professional

Engineer and submitted for approval prior to shipment.

C. Hydrostatic Test: Pump casing tested at 65 psi. Test pressure shall be maintained for no less than five minutes.

1.9 DELIVERY, STORAGE, AND HANDLING

A. Deliver, handle and store pumping system components in full accordance with manufacturer’s written instructions.

1.10 WARRANTY

A. Warranty: The SUPPLIER shall guarantee that all equipment, including all components of the complete assembly furnished by it hereunder, complies in all respects with the design and specifications of these documents and contains no defects of material or workmanship. In the event of failure of any part or parts of the equipment during the warranty period, due to defects of design, materials, or workmanship, the affected part or parts shall be replaced promptly upon notice by the OWNER. All replacement parts shall be furnished, delivered, and installed at the expense of the SUPPLIER.

B. The warranty period shall be interpreted as the period following the final acceptance of the installed equipment by the OWNER, and shall be exclusive of the time of use of the equipment installation, testing, adjusting, etc., during the construction period, of beneficial use by the OWNER or of the time in storage, after delivery and prior to installation. Final acceptance will not be issued by the OWNER until after successful completion of the performance acceptance test. Before the OWNER can issue the final acceptance, the manufacturer must submit the installation report that includes the methods, results, and conclusions from the performance acceptance test. Equipment shall be operated for a minimum of 30-days after equipment startup before final acceptance. 1. Warranty Period: Two years following final acceptance by OWNER.

C. Universal Joint Warranty. The universal joint shall carry a separate warranty of 10,000 operating hours. This warranty shall be unconditional in regards to damage or wear.

1.11 EXTRA MATERIALS

A. Furnish extra materials that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Seepex Series BN, SCT 2. Moyno EZ Strip

2.2 PUMPING UNIT CONSTRUCTION

A. General Description: 1. Pumping unit shall be of the heavy duty, positive displacement, single-stage,

progressive cavity type with a jointed drive train.

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2. Pump shall allow the normally vertical suction port to be rotated at 90-degree angles perpendicular to the centerline to facilitate piping connections.

3. Bearing and suction housings of the pump shall be thick-walled cast iron. All cast parts will be free of sand holes, blow holes, and other defects.

4. Suction housing shall incorporate two rectangular inspection ports, 180 degrees apart, to permit access to the suction housing interior without disconnecting piping to allow unrestricted 360º access for disassembly and maintenance in place.

5. Suction and discharge connections shall be flat or raised face flanges with bolt hole dimensions and spacing to ANSI standards. Coordinate suction direction as shown on the drawings. a. Suction Flanges on Belt Filter Press Feed Pumps: Min. 6-inch ANSI 16.5, 125 lb. b. Discharge Flanges on Belt Filter Press Feed Pumps: 6-inch ANSI 16.5, 125 lb. c. CONTRACTOR to coordinate piping size and fittings to match connection size.

B. Rotor: 1. One piece tool steel with 11.5 to 13.5 percent chromium content, hardened to 57 to 60

Rockwell C, with 0.010-inch hard chrome plating minimum double coated, 70 Rockwell C hardness, or the pump rotors shall be constructed of hardened tool steel with a chromium nitride coating (Duktil process) with a minimum thickness of (.0108").

2. Machined and polished single helix. 3. Rotors shall be replaceable without dismantling the pump suction or discharge flanges

or associated piping. Pumps that require additional space for axial/horizontal removal of the rotor shall not be allowed. The rotor design shall include provisions so that rotor replacement does not require the disassembly of either universal joint.

C. Stator: 1. Double helix configuration, molded nitrite elastomer, Shore A durometer hardness of 70

± 3, chemically bonded to the inside of a carbon steel tube. Alternatively, a split case stator assembly may be mechanically fastened to a carbon steel tube.

2. Secured to suction housing and discharge flange with removable clamp rings or tie rods.

3. The stator seals shall be designed to prevent the material being pumped from contacting the stator bonding and tube.

4. Stators shall be replaceable without dismantling the pump suction or discharge flanges or any associated piping. Pumps that require additional space for axial/horizontal removal of the stator shall not be allowed. Stator designs shall additionally incorporate a retensioning feature to compensate for wear in lieu of increasing pump speed.

D. Drive Unit: 1. Consists of a connecting rod connecting joints of the drive shaft and eccentrically

moving rotor. 2. Connecting Rod:

a. Shaft shall be solid through the seal area and allow the seal and all other wetted rotating parts to be removed from the pump without disassembly of the pump or gear motor bearings, or

b. Shaft shall pass through the shaft seal area inside the hollow drive shaft quill, preventing any eccentric loads imparted on shaft seal area.

c. Machined of alloy steel to accept a ball gear or pinned joint. 3. Joints:

a. Each pump rotor shall be driven through a positively sealed and lubricated pin joint. The pin joint shall have replaceable bushings, constructed of air-hardened tool steel of 57-60 HRc, in the rotor head and coupling rod. The pin shall be constructed of high speed steel, air hardened to 60-65 HRc. The joint shall be grease lubricated with a high temperature (450°F), PTFE filled synthetic grease, covered with Buna N sleeve and positively sealed with hose clamps constructed of 304 stainless steel. Alternatively, the pin joint may be oil filled.

b. Totally enclosed, protected by elastomeric seal.

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c. Mechanical Components Life: 10,000 hours at manufacturer’s published maximum rates.

E. Bearings: 1. Outboard End: Tapered roller thrust bearing. 2. Inboard End: Tapered roller radial bearing. 3. Rated Life: L-10 life 100,000 hours as defined by ABMA Standards. 4. Located in gearbox. 5. Lubrication: Oil, with addition and relief fittings. 6. Or each pump shall be provided with oil lubricated thrust and radial bearings, located in

the gear motor, designed for all loads imposed by the specified service. Minimum bearing L-10 shall be 100,000 hrs.

F. Stuffing Box: 1. Design: Integrally cast, allowing for use of packing or mechanical seals without re-

machining. Non-integral seal casings are also acceptable. 2. Provide with single internal Chesterton mechanical seal.

G. Baseplate: 1. Provide a common baseplate of cast iron or fabricated steel. 2. Constructed to support the full weight of pump, motor and drive assembly. Baseplate

and shall be provided with grout fill and venting holes. Base shall have anchor bolt holes drilled.

3. Provide an in-line, close-coupled between pump body and motor. 4. Provide an enclosed protective stainless steel plates to cover the rotating components. 5. Furnish connection for a casing drain. 6. Factory mount pump, gear unit, and driver.

2.3 MOTORS

A. Comply with NEMA designation, temperature rating, service factor, enclosure type, and efficiency requirements for motors specified in Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below”. 1. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven loads

will not require motor to operate in service factor range above 1.0. 2. Controllers, Electrical Devices, and Wiring: Comply with requirements for electrical

devices and connections specified in Division 16 Sections. 3. Requirements of this Section supersede any conflicting requirements of the specified

Division 11 Section.

B. If a motor horsepower rating larger than specified is offered as a substitute and accepted, provided required changes in conductors, motor controllers, overload relays, fuses, switches and other related items with no change in the Contract price.

C. Thermistors 1. Refer to Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below” for

thermistor requirements

2.4 ACCESSORY EQUIPMENT

A. Equipment Identification Plate: 16-gauge Type 316 stainless steel with 1/4-inch die-stamped equipment tag number securely mounted in a readily visible location.

B. Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 100 pounds shall be provided with lifting lugs

C. Anchor Bolts: Provide template and Type 316 stainless steel anchors in accordance with Division 5 Section “Anchor Bolts, Expansion Anchors, and Concrete Inserts” and as shown on the Drawings. Size as required by pump manufacturer.

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D. Initial Supply of Lubricants: Manufacturer shall indicate types, brands, and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment. CONTRACTOR shall provide and install the recommended lubricants and shall comply with all manufacturer recommended procedures.

E. Flow Detection Control Unit 1. Description: Consists of a sensor, a pressure switch, and run dry protection to prevent

damage from either run-dry conditions, or high-pressure conditions, and seal water failure. Controls shall be included in the pump control panel supplied by the CONTRACTOR.

2. Sensor: Installed between two standard ANSI flanges, same size as discharge piping. Mounted on sensor are the pressure switch and a liquid filled gauge.

3. Pressure switch for High Pressure and Run Dry Protection: The equipment manufacturer, or his representative, shall furnish with the process equipment, a high pressure/run dry (low pressure) protector. The control shall utilize a pressure sensor/isolator to separate the process fluid from the pressure sensing instrumentation. The process fluid pressure shall be transmitted by liquid silicone oil sealed between a carbon steel housing and a flexible elastomer element of nitrile. The pressure shall be monitored by a non-indicating pressure switch in a NEMA-4 enclosure. The pressure switch shall be dual set point, to stop the pump if low pressure (indicating no flow) or high discharge pressure occurs. The pressure sensor elastomer element shall have integrally molded flange face gaskets and lip seals and shall be compatible with 125-lb. ANSI flanges. The pressure sensor shall be mounted on the discharge flange of the pump.

2.5 FACTORY FINISH

A. All equipment items except stainless steel shall receive surface preparation, prime coating and finish coating in the factory in accordance with Section 09910 “Painting and Protective Coatings.” Finish coating colors shall be selected by the OWNER from finish color charts to be provided in shop drawing submittals. Furnish one gallon of touch up paint for installation CONTRACTOR to apply.

B. All stainless steel surfaces shall be cleaned and welds shall be brushed with 304 stainless steel brushes. Glass bead blast or chemically treat all external non-welded stainless steel to a uniform finish.

C. Motors and hydraulic units shall have manufacturer’s finish.

PART 3 - EXECUTION

3.1 GENERAL

A. Install and adjust equipment in accordance with the Drawings, approved shop drawings, and the manufacturer's instructions. Do not operate the equipment until the installation is approved by the manufacturer’s representative.

3.2 INSTALLATION

A. Install in accordance with manufacturer’s printed instructions, the requirements of Division 1 and as described herein.

B. Level baseplate by means of steel wedges (steel plates and steel shims). Wedge taper not greater the 1/4-inch per foot. Use double wedges to provide a level bearing surface. Accomplish wedging so that there is no change of level or springing of the base elbow when anchor bolts are tightened.

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C. Adjust pump assemblies such that the driving units are properly aligned, plumb, and level with the driven units and all interconnecting shafts and couplings. Do not compensate for misalignment by use of flexible couplings.

D. After the pump and driver have been set in position, aligned, and shimmed to the proper elevation, grout the space between the bottom of the baseplate and the concrete foundation with a poured, non-shrinking grout of the proper category, as specified in Section 03600 “Grout”. Remove wedges after grout is set and pack void with grout.

E. Complete equipment installation with controls, safety devices and auxiliary support systems necessary to start the equipment and verify that the equipment functions correctly under no load conditions. Turn rotating equipment by hand to check. Complete cleaning and testing of piping systems. Inspect and clean equipment, devices, piping, and structures of debris and foreign material.

F. Remove temporary bracing supports and other construction debris that may damage equipment.

G. Remove protective coatings and oils used for protection during shipment and installation.

H. Flush, fill, and grease lubricated systems in accordance with Manufacturer's instructions.

I. Install temporary connections and devices required to fill, operate, checkout and drain the system. Provide temporary valves, gauges, piping, test equipment, and other materials and equipment necessary to conduct testing and startup.

J. Equipment 1. Check equipment for correct direction of rotation and freedom of moving parts. 2. Align equipment to Manufacturer's tolerances. Adjust clearances and torques. 3. Check installation prior to start-up for conformance to Manufacturer's instructions. 4. Adjust or modify equipment to ensure proper operation.

K. Correct any deficiencies or problems noted in Manufacturer's representative's installation reports.

3.3 MANUFACTURER’S SERVICES

A. Manufacturer’s Representative: The equipment manufacturer shall furnish a qualified field representative to inspect all equipment described herein after installation to assist in troubleshooting, to advise contractor during start-up and testing, and to instruct OWNER’s personnel in routine maintenance and troubleshooting procedures for the minimum person-days listed below:

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No. Person Days Work Description

1 Installation assistance and inspection. 1 Functional and performance testing. 1 Pre-startup classroom or site training.

1/2 Facility startup. 1 Post-startup training of OWNER’S personnel.

This period shall consist of a minimum of 8-hour days and travel to and from the project site shall not be included. The CONTRACTOR shall coordinate the scheduling of such training and start-up assistance with OWNER’s personnel.

B. Services Provided: 1. Furnish test forms and procedures for field-testing. 2. Furnish startup services. 3. Furnish training of OWNER’S personnel at such times requested by OWNER.

C. Manufacturers services shall comply with the requirements of Section 01640 “Manufacturer’s Services” and training shall comply with the requirements of Section 01820 “Demonstration and Training.”

3.4 FIELD QUALITY CONTROL

A. Functional Tests: Conduct on each pump as described below and in accordance with Section 01810 “Equipment Testing and Facility Startup.” 1. Alignment: Test complete assemblies for correct rotation, proper alignment and

connection, and quiet operation.

B. Performance Test: In accordance with Hydraulic Institute Standards. 1. Place each piece of equipment in the system in operation until the entire system is

functioning. All components shall continue to operate satisfactorily without excessive power input, wear, lubrication, or undue attention required for this operation, vibration or noise at any operating speed and head, and without any alarms or shut downs for eight (8) consecutive hours to be considered started up.

2. Operate the equipment through the design performance range consistent with available flows. Adjust, balance, and calibrate and verify that the equipment, safety devices, controls, and process system operate within the design conditions. Each safety device shall be tested for proper setting and signal. Response shall be checked for each equipment item and alarm. Simulation signals may be used to check equipment and alarm responses.

C. A copy of all information from functional tests, including data, worksheets, and other materials shall be turned over to the OWNER at the completion of the testing program.

3.5 START-UP AND FINAL ACCEPTANCE

A. Startup of the facility shall be in accordance with Division 1. After initial startup under the supervision of a qualified representative of the manufacturer, a preliminary “running-in” period will be provided for the CONTRACTOR, per the Contract Documents, to make field tests and necessary adjustments.

B. The equipment shall continue to operate without alarms or shut downs, except as intended, for ten (10) consecutive days to be considered started up.

C. Operate the equipment through the design performance range consistent with available flows. Adjust, balance, and calibrate and verify that the equipment, safety devices, controls, and process system operate within the design conditions. Each safety device shall be tested for proper setting and signal. Response shall be checked for each equipment item and alarm. Simulation signals may be used to check equipment and alarm responses.

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D. At the end of the specified period of operation, the equipment system will be accepted if, in the opinion of the ENGINEER, the system has operated satisfactorily without excessive power input, wear, lubrication, or undue attention required for this operation, and if all rotating parts operate without excessive vibration or noise and the desired performance has been obtained.

E. Manufacturer's installation report and complete and Final Operation & Maintenance Manuals are required prior to final acceptance.

3.6 SUPPLEMENT

A. The Pump Data Sheet included after “END OF SECTION” shall be part of this Section.

END OF SECTION

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PUMP DATA SHEET

Equipment Tag Number(s) BFP No. 1, No. 2 Quantity 2 Pump Name Belt Press Feed Service Conditions Liquid Pumped Unthickened blended sludge % Solids 0.5-1.0 Viscosity N/A Corrosion or Erosion Factors: pH = 6-8, Abrasive Pumping Temperature, °F Indoors Performance Requirements

Rated Capacity 200 gpm at 20 psi differential pressure

Lowest Capacity Required 100 gpm at 14 psi differential pressure

Pump Speed, rpm (max) 350 Motor, HP (Max) 15 Motor Speed, rpm 1,750 Drive Configuration Helical inline gear Power Supply 460 V/3 phase/60 Hz Operation Variable Frequency Drive Pump Construction Details Number of Stages 1 Suction (Size) 6-inch (Min.), 150 lb Discharge (Size) 6-inch, 150 lb Hydrostatic Factory Test Pressure Field Testing (Required/Not Required) Yes

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SECTION 11074 PUMP, END SUCTION CENTRIFUGAL

PART 1 - GENERAL



1.2 SUMMARY

A. Furnish, install, startup, and test two (2) horizontal, end suction, single stage, centrifugal pumps (WBP-1, and -2) to boost the pressure of plant water for belt press filter washdown complete and operable with pump base, appurtenances, and all other components required to meet the specified pumping conditions, as shown on the plans and specified herein.

B. Section Includes: 1. Horizontal, end suction single stage centrifugal pumps. 2. Installation, startup, testing, and placing in service assistance. 3. Training of Owner’s personnel.

1.3 REFERENCES AND DEFINITIONS

A. References: Following is a list of standards, which might be referenced in this Section: 1. Antifriction Bearing Manufacturers Association (AFBMA):

a. 9 – Load Ratings and Fatigue Life for Ball Bearings. b. 11 – Load Ratings and Fatigue Life for Roller Bearings.

2. American National Standards Institute/American Society of Mechanical Engineers (ANSI/ASME):

a. B15.1 – Safety Standard for Mechanical Power Transmission Apparatus. b. B16.5 – Pipe Flanges and Flanged Fittings. c. B73.1 – Specifications for Horizontal End Suction Centrifugal Pumps for

Chemical Process. 3. American National Standards Institute/Hydraulic Institute (ANSI/HI):

a. 1.1-1.5 – Centrifugal Pumps - Nomenclature, Definitions, Application and Operation.

b. 1.6 – Centrifugal Pump Tests. c. 9.1-9.5 – Pumps – General Guidelines for Types, Definitions, Application and

Sound Measurement. 4. ASTM International (ASTM):

a. A 48 - Specification for Gray Iron Castings b. A 276 – Specification for Stainless and Heat Resisting Steel Bars and Shapes. c. A 395 – Specification for Ferritic Ductile Iron Pressure-Retaining Castings for

Use at Elevated Temperatures. d. A 536 – Specification for Ductile Iron Castings

5. International Organization of Standardization (ISO): ISO 1940 – Balance Quality Requirements for Ridged Rotors.

6. National Electrical Manufacturer’s Association (NEMA): MG-1, Motors and Generators.

7. National Fire Protection Association (NFPA): NFPA 70, National Electric Code.

B. Definitions: 1. Pump Head (Total Dynamic Head), Flow Capacity, Pump Efficiency, Net Positive

Suction Head Available, and Net Positive Suction Head Required: As defined in ANSI/HI 1.1-1.5 and 9.1-9.5 and as modified in this Section.

2. Suction Head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.

3. Tolerances: In accordance with Hydraulic Institute 1.1-1.5, 1.6, and 9.1-9.5, unless specified more restrictively.

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A. Design Requirements: 1. Summary:

a. Two booster pumps (WBP-1, and -2) to be installed in the Dewatering Building to provide wash water at the desired pressure and flow to the belt filter presses.

B. Service Conditions: 1. Liquid Pumped: Non-Potable Plant Water 2. Pumps shall have a head-capacity curve that is continuously increasing within the

operating range of the pump from maximum capacity to shutoff head. 3. Refer to Pump Data Sheet for additional information.


A. Guaranteed Performance: 1. Transfer the product at the operating conditions as listed in the Pump Data Sheet and

as shown on the Pump Curve(s). 2. Comply with performance requirements specified, as determined by

testing assemblies representing those indicated for this Project.

1.6 WARRANTY


B. The warranty period shall be interpreted as the period following the final acceptance of the installed equipment by the OWNER, and shall be exclusive of the time of use of the equipment installation, testing, adjusting, etc., during the construction period, of beneficial use by the OWNER or of the time in storage, after delivery and prior to installation. Final acceptance will not be issued by the OWNER until after successful completion of the performance acceptance test. Before the OWNER can issue the final acceptance, the manufacturer must submit the installation report that includes the methods, results, and conclusions from the performance acceptance test. Equipment shall be operated for a minimum of 30-days after equipment startup before final acceptance.

1. Warranty Period: Two years following final acceptance by OWNER.

1.7 SPARE PARTS AND TOOLS

A. Furnish and apply an initial supply of grease and oil as required by the manufacturer.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Aurora Pumps. 2. Flowserve Corporation. 3. Goulds Pumps. 4. Cornell.

2.2 PUMP CONSTRUCTION

A. Type: 1. Horizontal close-coupled end suction centrifugal pump, complete with motor coupling,

guard, and appurtenances mounted on a common base plate.

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2. Pump shall comply with the requirements of ASME B73.1.

B. Materials: 1. Casing: Cast Iron, ASTM A 48, Class 30 minimum or Cast Ductile Iron, ASTM A 395

and A 536. 2. Impeller: Bronze, SAE 40, ASTM B584, C83600 3. Shaft: Steel, AISI C1045. 4. Shaft Sleeve: Bronze, ASTM B144-3B, C93200. 5. Case Wear ring: Bronze, ASTM B144-3B, C93200. 6. Power Frame: Cast Iron, ASTM A 48, Class 30 minimum or Cast Ductile Iron, ASTM

A 395 and A 536.

C. Casing: 1. Type: End suction, tangential discharge design. Pump shall have a volute type casing

suction. 2. Suction and Discharge Flanges: Threaded, NPT connections. Size as indicated in

Pump Data Sheet. 3. Corrosion Allowance: Provide a corrosion allowance of 0.12 inches minimum. 4. Hydrostatic test: Ten (10) minute hydrostatic test at minimum 1.5 times Design

Working Pressure. 5. Gasket(s): Casing-to-cover gasket(s) shall be confined on the atmospheric side to

prevent blowout

D. Impeller: 1. Type: Open, Semi-open, or Closed as indicated on Pump Data Sheet. 2. Balance: Impellers shall meet ISO 1940 Grade 6.3 or better after final machining. 3. Attachment: The impeller may be keyed or threaded to the shaft with rotation to

tighten. Shaft threads and keyways shall be protected so they will not be wetted by the pumped liquid.

E. Shaft/Shaft Sealing: 1. Bronze or Type 303 stainless steel keylocked shaft sleeve that extends the length of

the seal box. The pump shaft extension shall be O-ring sealed from the pumped liquid.

2. Provide either a seal chamber or a stuffing box as described below. 3. Seal Chamber:

a. Cylindrical or a tapered design in accordance with ASME B71.2. b. Bore corners and entry holes, such as those used for flushing or venting, shall

be suitably chamfered or rounded to prevent damage to secondary seals at assembly.

c. Provide a means of eliminating trapped air or gas. Vent connections located at the highest point; drains located at the lowest point.

d. Piping connections to the seal and seal gland; 1/4-inch NPT minimum. 4. Stuffing Box:

a. Packing bore surface shall not exceed a roughness of 63 µinch. One lantern ring connection shall be provided.

b. Sized to maintain the stuffing box bore concentric with the axis of the pump shaft and stuffing box face perpendicular to the axis of the assembled pump shaft in accordance with ASME B73.2.

c. Designed for installation and operation of mechanical seals, including means of eliminating trapped air or gas at the highest practical point.

5. Seals: a. Shaft Seal: Double mechanical seal; metal parts constructed of Type 303

stainless steel, Ni-Resist or ceramic seats, carbon washer, and Buna-N secondary sealing elements.

b. Packing Gland: Cast iron O-ring seated. c. Seal Water: Provide seal water connection. d. Drain: Minimum 3/8-inch size, with drain line to nearest equipment floor drain.

F. Wear Rings: Provide casing and stuffing box cover with wear ring. Case wear ring will be of the radial type, press-fitted into the case.

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2.3 MOTORS

A. Comply with NEMA designation, temperature rating, service factor, enclosure type, and efficiency requirements for motors specified in Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below.”

1. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven loads will not require motor to operate in service factor range above 1.0.

2. Controllers, Electrical Devices, and Wiring: Comply with requirements for electrical devices and connections specified in Division 16 Sections.


2.4 CONTROL PANEL CONSTRUCTION REQUIREMENTS

A. Refer to Section 16486 Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs), for the construction requirements of each Control Panel. All panels specified under this Section, shall be submitted as a part of each associated mechanical equipment submittal.

2.5 FINISH

A. Provide polyurethane, pigmented (over epoxy zinc rich primer and high build epoxy) in accordance with Section 09910 “Painting and Protective Coatings.” Pump shall receive surface preparation, prime coat and finish coat in factory.


A. In addition to the source quality control testing described in Section 11016 “Common requirements for Pumps,” perform the following testing:

1. Functional Test: Perform motor test on equipment. Include a vibration test, as follows: a. Dynamically balance rotating parts of each pump and its driving unit before final

assembly. b. Limits: Complete rotating assembly, including drive unit and motor, shall not

exceed twice the limits shown in Fig. 9.6.4.5 of ANSI/HI 9.6.4. 2. Performance Test: Conduct on each pump under simulated operating conditions in

accordance with ANSI/HI 1.6, level “A.”

PART 3 - EXECUTION


A. Manufacturer’s Representative: Present at Project site or classroom designated by OWNER, for minimum person-days listed below, travel time excluded:

B. Revise time in the Table below for manufacturer’s representative to be present to accomplish the various tasks as required for the work and Project. Delete if not required.


1 Installation assistance and inspection. 1 Functional and performance testing.

1/4 Pre-startup classroom or site training. 1/2 Facility startup. 1/4 Post-startup training of OWNER’S personnel.

3.2 SUPPLEMENT


END OF SECTION

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PUMP DATA SHEET

Equipment Tag Number(s) WBP No. 1, No. 2 Quantity 2 Pump Name Booster Pump Nos. 1 and 2 Service Conditions Liquid Pumped Plant Water Liquid Temperature, °F Max: 90 Min: 32 Specific Gravity 1.0 Abrasive (Y/N) N Possible Scale Buildup (Y/N) Y Explosion-proof (Y/N) N Continuous Duty (Y/N) N Performance Requirements Capacity at Primary Condition of Service, gpm 90 Total Head, ft. 150 Shutoff Pressure, Maximum, ft. 200 Pump Speed, Maximum, rpm 3600 Motor HP, Maximum 10 Voltage, Phase 480 VAC, 3-Phase, 60 Hertz Minimum Pump Efficiency at Design 54% Constant Speed (Y/N) Y Adjustable Speed (Y/N) N Pump Construction Details Suction (Size) 1.5”, min Discharge (Size) 1”, min Hydrostatic Test Pressure (psig) 125 psi Field Testing (Required/Not Required) Required Impeller Type (1) C Vent and drain connections tapped and plugged Not required

NOTES: (1) O = Open, SO = Semi-open, C = Closed

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VORTEX GRIT REMOVAL SYSTEM EQUIPMENT F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 11\11110 VORTEX GRIT REMOVAL SYSTEM_CE.DOC

SECTION 11110 VORTEX GRIT REMOVAL SYSTEM EQUIPMENT

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Provide, install, start up, and test two (2) baffles for installation in existing vortex units,

complete and operable per the orientation shown on the Plans and as specified herein. 2. Contractor and Equipment Manufacturer shall be responsible for coordinating the

testing and installation of the equipment.


A. Design Requirements: 1. Location: Preliminary Treatment Area 2. Quantity: 2 3. Capacity:

a. Average Influent Flow Rate: 5.0 MGD per unit. b. Design Flow Rate: 12.0 MGD per unit. c. Peak Flow Rate: 16.7 MGD per unit.

4. Baffles must fit within the dimensions of the existing Smith & Loveless Pistagrit units. Contractor shall coordinate with Manufacturer on placement, dimensions, and orientation of baffles to optimize grit removal efficiency.

5. Flow Direction: As shown on the Drawings.

B. Performance Requirements: 1. The integral flow control baffle shall enhance the grit removal effciency at the specified

hydraulic flow rate of 12 MGD, and no decrease in efficiency will be allowed at flows less than this design rate. The efficiency relates to grit having a Specific Gravity of 2.65 and to the difference in grit content in the inluent channel, as compared to that in the effluent channel. a. 95% of the grit greater than 140 mesh (106 microns) in size.

2. Hydraulic Loss: Less than 1/4-inch headloss at the specified hydraulic peak flow rate through the unit.

C. Structural Performance: 1. All equipment, supports, anchors and fasteners shall be of adequate size and strength

to withstand loads associated with turbulence, debris, thrusts from liquid movement, thermal expansion and contraction and other loads encountered under raw sewage operating conditions

D. Operation: Equipment shall be designed and capable of either continuous or intermittent operation.

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1.4 SUBMITTALS

A. Submittals shall be prepared and submitted in accordance with Division 1 “Submittal Procedures”.

B. Product Data: Provide construction details, material descriptions, dimensions of individual components and profiles, rated capacities, operating characteristics, electrical characteristics, and furnished specialties and accessories.

C. Shop Drawings: Provide plans, elevations, sections, details, and attachments to other work. The following information shall be included as a minimum. 1. Detail equipment assemblies and indicate dimensions, weights, loads, required

clearances, method of field assembly, components, and location and size of each field connection.

2. Layout, sizes, types and materials for anchor bolts to be furnished. 3. Location of any specified instrumentation equipment. 4. Documentation and test data on grit removal efficiencies for this size and configuration of

unit for flows from zero to maximum flow rates. 5. Wiring Diagrams: For power, signal, and control wiring diagrams, including terminals

and numbers if applicable. 6. Equipment weights and lifting points.

D. Operation and Maintenance Data: Provide in accordance with Section 01782 “Operation and Maintenance Data.”

E. Information Submittals: 1. Manufacturer’s Certification of Compliance. 2. Special shipping, storage and protection, and handling instructions. 3. Manufacturer’s instructions for installation. 4. Manufacturer’s Certificate of Proper Installation. 5. Qualification Data: Manufacturer and manufacturer’s representative. 6. Location of nearest stocking distributor of spare parts. 7. Suggested spare parts list to maintain the equipment in service for a period of one

year. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current pricing information.

8. Factory Test Reports: Based on evaluation of comprehensive tests performed by manufacturer.

9. Field quality-control reports. 10. Warranty: Sample of special warranty.

F. Submittals Quality Assurance/Control 1. All deviations from contract documents shall be clearly identified and approved in

writing by the ENGINEER. 2. Any other information necessary for the ENGINEER to determine compliance with the

specifications. 3. Partial or incomplete submittals will not be reviewed by ENGINEER


A. Manufacturer Qualifications: 1. All equipment shall be the product of a manufacturer having at least ten (10) U.S.

installations of the type being proposed, each with a minimum of 5 years of satisfactory service.


B. The equipment manufacturer shall furnish a qualified field representative for the time indicated in 3.6.A. Field representatives shall have a minimum of three (3) years of experience with the operation of and training on this type of equipment. Factory-employed

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personnel will be required to perform this service. Sales representatives will only be considered acceptable service technicians if they have three (3) years of experience with the operation of and training on this type of equipment from the manufacturer being supplied and have started up 15 units of a similar size and type from the manufacturer. The field representative shall submit a resume for approval before startup assistance can be provided. The CONTRACTOR shall coordinate the scheduling of such training and startup assistance with OWNER’s personnel.

C. Source Limitations: Equipment units of each type specified in this section shall be supplied by a single manufacturer.


A. Deliver, handle and store pumping system components in accordance with manufacturer’s written instructions and the requirements of Section 01600 “Product Requirements.”

1.7 PROJECT CONDITIONS

A. Grit Removal Basin Configuration: 1. Modifications to structural design due to a manufacturer’s varying dimensional, floor

slope requirements, or dimension changes to fit manufacturer specific requirements shall be coordinated by CONTRACTOR and included in the Bid. ENGINEER shall be reimbursed for all fees associated with structural redesign.

2. The CONTRACTOR shall be responsible for any modifications to the piping, pumps, electrical, structural, and mechanical layouts to accommodate, as well reimbursement to OWNER for additional charges by ENGINEER for additional work required to accomplish changes.

B. The equipment, sizes, materials, and arrangements described in this specification section are based on recommendations by equipment manufacturers and shall be considered minimum limits of acceptability. The equipment manufacturers shall be responsible for design, arrangement, and performance of all equipment supplied under this section.

C. Environmental Conditions: 1. All equipment including controls and drives specified herein shall be specifically

designed for this service and the environment encountered in this installation. 2. The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other

corrosive gases encountered in municipal wastewater treatment plants. 3. The equipment shall be of all-weather design, capable of operation at ambient

temperatures of 0°F to 110°F.

D. Field Measurements: CONTRACTOR shall verify actual locations of walls and other construction contiguous with metal fabrications by field measurements before fabrication and indicate measurements on Shop Drawings. 1. Established Dimensions: Where field measurements cannot be made without delaying

the Work, establish dimensions and proceed with fabricating metal fabrications without field measurements. Coordinate wall and other contiguous construction to ensure that actual dimensions correspond to established dimensions.

2. Provide allowance for trimming and fitting at site.

1.8 COORDINATION

A. Coordinate installation of anchorages for metal fabrications. Furnish setting drawings, templates, and directions for installing anchorages, including sleeves, concrete inserts, anchor bolts, and items with integral anchors, which are to be embedded in concrete or masonry. Deliver such items to Project site in time for installation.

1.9 WARRANTY

A. Special Equipment Warranty:

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1. The equipment manufacturers shall jointly warrant to the OWNER and to the CONTRACTOR that all equipment, including all components of the complete assembly furnished by it hereunder, complies in all respects with the design and specifications of these Documents and contains no defects of material or workmanship.

2. In the event of failure of any part or parts of the equipment during the warranty period due to defects of design, materials, or workmanship; the CONTRACTOR shall replaced affected part or parts shall be replaced promptly upon notification by the OWNER. All replacement parts shall be furnished, delivered, and installed at the expense of the equipment manufacturer.

3. The warranty period shall be interpreted as the 24-month period following the final acceptance of the installed equipment by the OWNER and shall be exclusive of the time of use of the equipment in installation, testing, adjusting, etc., during the construction period, or of the time in storage, after delivery and prior to installation. Provisional acceptance of the equipment shall not affect the determination of the first year of service. All equipment shall be operated for a minimum continuous successful 30-day start-up period before final acceptance and before the start of the 24-month warranty period.

4. If the equipment does not meet the requirements of the Specifications, the equipment manufacturer shall correct or service the equipment at no additional cost to meet the specified requirements, where any such deficiencies are the responsibility of the equipment manufacturer. In the event the equipment is unable to meet the specified requirements within the warranty period, the equipment manufacturer shall refund an amount equal to the purchase price of new equipment, which will meet the specific requirements. The amount of the refund shall not exceed the purchase price of the equipment to be replaced.

5. The CONTRACTOR shall be responsible for insuring that the manufacturer's special equipment warranty is not voided by acceptance of the terms of purchase agreements between the CONTRACTOR and the MANUFACTURER. In all events, the CONTRACTOR will be held ultimately responsible for enforcement of the requirements of this warranty at his expense.

6. Payment for equipment as "Materials-On-Hand" will not be made until the OWNER receives an approved Special Equipment Warranty.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. The acceptable equipment shall be the V-Force Baffle manufactured by Smith and Loveless, Inc., Lenexa, Kansas. The representative for Smith and Loveless, Inc., for this area is Newman Regency Group, 4011 West Plano Parkway, Suite 108, Plano Texas 75093, Telephone No. (972)769-1993. A not-to-exceed price letter is attached to the end of this section.

2.2 GRIT BAFFLE DESCRIPTION:

A. Construction: 1. Sized and constructed in accordance with the manufacturer’s drawings to proper

retention time and an adequate flow pattern, in order to maximize grit removal.

2.3 EQUIPMENT

A. Fabrication: 1. Material: Type 316 stainless steel plate. 2. Welds: Fillet welds at least 1/4 inch. 3. Gusset all bolted connections with stainless steel plate at least 3/8-inch thick. 4. Use a minimum 5/8-inch bolts for connections. 5. All bolts shall be Type 316 stainless steel.

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6. Only bolted connections may be made in the field.

2.4 FINISHES

A. Select the finish coating for the equipment based on location, substrate, and environment. Refer to Section 09910 “Painting and Protective Coatings” for information.

2.5 ACCESSORIES

A. Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 100 pounds shall be provided with lifting lugs.

B. Anchorage and Fasteners: Anchor bolts shall be the embedded hook-type or capsule or epoxy anchor-type minimum ½” inch diameter. All anchor bolts, and fasteners shall be Type 316 stainless steel. Supplier shall determine number and size of anchor bolts, furnish templates where necessary and furnish anchor bolts.

C. Initial Supply of Lubricants: Manufacturer shall indicate types, brands, and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment. CONTRACTOR shall provide and install the recommended lubricants and shall comply with all manufacturer recommended procedures.


A. Factory Tests: Testing and inspection of factory assembled unit shall be accomplished by manufacturer prior to shipment. Upon satisfactory completion of testing, the units will be disassembled into subcomponent assemblies for shipment and installation.EXECUTION

3.1 GENERAL

A. Install and adjust equipment in accordance with the Drawings, approved shop drawings, and the manufacturer's instructions. Do not operate the equipment until the installation is approved by the manufacturer’s representative.

B. Comply with the requirements of Section 01700 “Execution Requirements.”

3.2 ASSEMBLY AND INSTALLATION

A. Assemble and install equipment in accordance with the manufacturer's instructions. 1. Do not cut or weld any stainless steel component in the field. Violation of this

requirement will result in rejection of affected components. 2. Remove temporary bracing supports and other construction debris that may damage

equipment. 3. Remove protective coatings and oils used for protection during shipment and

installation. 4. Check equipment for correct direction of rotation and freedom of moving parts. 5. Align equipment to Manufacturer's tolerances. Adjust clearances and torques. 6. Adjust or modify equipment to ensure proper operation. 7. Flush, fill, and grease lubricated systems in accordance with Manufacturer's

instructions.

B. Touch up scratches and scrapes in painted surfaces in accordance with Division 9.

C. Check installation prior to start-up for conformance to manufacturer's instructions. Adjust or modify equipment to ensure proper operation.


A. Functional Tests: Prior to plant startup, the CONTRACTOR, with the assistance of the manufacturer’s representative, shall inspect all equipment for proper assembly and alignment, quiet operation, and proper operation.

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B. Performance Test: The manufacturer’s representative shall conduct performance test on the equipment to certify compliance with the performance requirements. 1. Place each piece of equipment in the system in operation until the entire system is

functioning. All components shall continue to operate without alarms or shut downs, except as intended, for eight consecutive hours to be considered ready for facility startup.



3.4 DEMONSTRATION GRIT REMOVAL EFFICIENCY

A. General Approach: 1. One grit removal unit (GRU) shall be tested to verify removal efficiencies. Initial testing

shall be accomplished with the required influent flows diverted through GRU to be tested at the required flow rates.

2. 2. MANUFACTURER shall provide testing equipment, all personnel in relation to testing, and will enlist an independent third party to perform the analysis. MANUFACTURER will be on site to operate units during test.

B. Sampling; Percent Grit Removal: 1. Samples shall be taken concurrently from both the influent and effluent of the grit

removal unit. The sample points shall be across the width of the inlet and exit channel, with the inlet samples taken directly ahead of the ramp and the exit samples taken at the exit of the GRU.

2. Six samples will be obtained in evenly spaced intervals across the bottom of each influent and effluent channel. Six additional samples at approximately the center of the flow area will be obtained in evenly spaced intervals across each influent and effluent channel. This will result in 12 influent and 12 effluent samples for each GRU.

3. Flow shall be monitored and maintained at approximately design flow rate for the length of the test.

C. Test Procedure for Influent Channel: 1. The following test procedure is for one individual sampling point in the influent channel.

The procedure shall be repeated at every sample position. 2. A 1-inch minimum diameter sample pipe shall be installed at each sample point and

clamped into position. The sample shall be siphoned if at all possible or, as an alternative if siphoning is not possible, diaphragm pumps shall be used that will ensure sufficient velocity to keep the grit in suspension in the sample line.

3. The sample discharge line shall be inserted in a 30-gallon minimum garbage can located so the overflow can drain. The discharge end of the hose shall be positioned and clamped to the can so that the discharge does not sweep the bottom of the can.

4. Liquid shall be allowed to discharge into the can for a sufficient amount of time to capture 20 to 25 grams of sample influent in the influent settling basin from each sample point in the influent channel. If the grit sample is too small or too large, the time interval shall be adjusted.

5. Once a time interval is established, it shall be recorded and used in all testing. Flow through the sample lines shall be monitored to ensure full flow at all times. At the end of the time interval, the discharge hose shall be removed from the can.

6. The grit in the can shall be allowed to settle for a minimum of two (2) hours prior to tilting the can and pouring the liquid contents out slow enough as to not to disturb any

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settled grit on the bottom of the can. One (1) to four (4) inches of liquid shall be left above the accumulation of grit in the bottom of the can.

7. The liquid, grit and organics remaining in the can shall be poured through a coarse screen or colander to remove the larger organics and the material passing captured in a five (5) gallon bucket. The settling basin shall be thoroughly rinsed to ensure all the grit is washed into the five-gallon bucket.

8. As each influent sample is collected, it will be combined with the previously collected influent samples in the five-gallon bucket.

D. Lab Procedure for Influent Channel: 1. The contents of the five gallon bucket shall be allowed to settle for a minimum of two

hours and shall have all of the excess water and floating organics poured off it, being careful to ensure that no grit is lost.

2. The remaining material shall be poured onto a 200-mesh sieve. The residue on the 200-mesh sieve shall be washed repeatedly with a slow stream of clean water while working the sieve surface with a plastic scraper. The material shall be washed to the side of the sieve.

3. The material contained on the sieve shall be transferred from the sieve into a crucible of a size sufficient to contain it. The transfer shall be by scraping the sample using the scraper.

4. The crucible shall be placed immediately on a flask heater for a period of time sufficient to both dry and burn off all the organic material contained in it. After cooling the material remaining in the crucible shall be processed to determine the size and quantity of the grit captured.

5. The grit from the crucible shall be poured onto a 140-mesh sieve. The sieve shall be shaken by hand, tilted back and forth, and brushed with a short bristle brush to ensure that friable ash is broken and that the fines pass through the sieves.

6. The grit remaining on each sieve shall be separately placed into tared aluminum weight boats for weighing. The contents shall then be weighed to determine the 140-mesh grit weights. These will be tabled and reported as the influent grit weights in grams by mesh size.

7. All testing procedures shall comply with ASTM Standard D 422 where applicable.

E. Test Procedure for Effluent Channel: 1. Testing for the effluent channel will be done in exactly the same manner as specified

above for the influent channel. Each sample point shall be sampled for the amount of time it took to collect 20 to 25 grams of influent grit. This will ensure that the influent and effluent channels were sampled for a similar period of time. The effluent channel shall be sampled concurrently with the influent channel.

F. Lab Procedure for Effluent Channel: 1. The lab procedure for the effluent channel will be done in exactly the same manner as

specified above for the influent channel. The contents shall then be weighed to determine the 140-mesh grit weights. These will be tabled and reported as the effluent grit weights in grams by mesh size.

G. Grit Removal Efficiency Determination: 1. The effluent sample weight for each mesh size shall be subtracted from the influent

sample for the corresponding mesh size and the result shall then be divided by the same influent sample weight. The result shall be multiplied by 100 indicating the percent removal for each mesh size. This shall be tabulated and reported for each mesh size.

2. All of the effluent sample weights shall be summed for a total effluent sample weight independent of mesh size. All of the influent sample weights shall be summed for a total influent sample weight independent of mesh size. The total effluent sample weight shall be subtracted from the total influent sample weight and the result shall be divided by the total influent sample weight and then multiplied by 100. This will give a total removal efficiency of the GRU.

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H. Grit Removal Efficiency Penalty: 1. This efficiency shall not be less than the specified removal percentages. If the testing

procedure yields a grit removal efficiency of less than 90% of the specified removal percentages, the following penalties shall apply: a. If the grit removal efficiency of the unit is greater than or equal to 81% and less

than or equal to 89%, a performance penalty of 10% of the bid price of the equipment shall be deducted from the bid price.

b. If the grit removal efficiency of the unit is less than or equal to 80%, a performance penalty of 20% of the bid price of the equipment shall be deducted from the bid price.

I. The MANUFACTURER shall furnish the CONTRACTOR, OWNER and ENGINEER with four (4) certified copies of the final test report within one week of the performance testing.

3.5 MANUFACTURERS’ CERTIFICATES

A. Provide equipment manufacturer’s Certificate of Installation stating that the equipment is installed per the manufacturer’s recommendations and in accordance with the Drawings and Specifications.

B. Provide equipment manufacturer’s Certificate of Performance stating that the equipment meets or exceeds the performance requirements as defined hereinbefore.




1 Installation assistance and inspection. 4 Functional and performance testing.

1/2 Pre-startup classroom or site training. 1 Facility startup.

1/2 Post-startup training of OWNER’S personnel.

B. Services Provided: 1. Furnish test forms and procedures for field testing. 2. Furnish startup services. 3. Furnish training of OWNER’S personnel at such times requested by OWNER.

C. Manufacturers services shall comply with the requirements of Section 01640 “Manufacturer’s Services” and training shall comply with the requirements of Section 01820 “Demonstration and Training.”

3.7 FACILITY STARTUP

A. Startup of the facility shall be in accordance with Section 01810 “Equipment Testing and Facility Startup.” After initial startup under the supervision of a qualified representative of the manufacturer, a preliminary “running-in” period will be provided for the CONTRACTOR, per the Contract Documents, to make field tests and necessary adjustments.

B. Place each piece of equipment in the system in operation until the entire system is functioning. All components shall continue to operate without alarms or shut downs, except as intended, for five (5) consecutive days to be considered ready for facility startup.


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D. Prepare manufacturer's installation report and submit within 30 days after completion of field testing. Including the following information: 1. Field testing results. 2. Descriptions of installation deficiencies not resolved to the manufacturer's satisfaction. 3. Description of problems or potential problems. 4. Names of the OWNER'S personnel who attended operations and maintenance training

sessions. 5. Record copy of materials used for training session including outlined summary of

course. 6. Manufacturer’s Certificate of Installation and Certificate of Performance.

E. At the end of the specified period of operation, the equipment system will be accepted if, in the opinion of the ENGINEER, the system has operated satisfactorily without excessive power input, wear, lubrication, or undue attention required for this operation, and if all rotating parts operate without excessive vibration or noise and the desired removal efficiency has been obtained.

END OF SECTION

Not-to-Exceed Letter to be Added

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F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 11\11144_BELT FILTER PRESS.DOCX

SECTION 11144 BELT FILTER PRESS

PART 1 - GENERAL



1.2 SUMMARY

A. Furnish, install, startup and test two (2) belt filter presses, complete and operable with all appurtenances, components and controls, as shown on the plans and specified herein. The equipment to be furnished under this section of the Specifications shall consist of refurbishing one (1) 2.0-meter belt filter press (BF-1) with all ancillary items in the Dewatering Building and supplying one (1) new 2.0-meter belt filter press (BF-2). The components to be refurbished or replaced shall include, but not be limited to, the following major items: 1. Belt Filter Press No. 1 (BF-1) shall be dismantled in the field, shipped to the

manufacturer’s facility, refurbished in the shop, returned, and reassembled in place in the dewatering building. Items to be replaced and refurbished include but are not limited to the following: a. Replacement items:

1) Belts 2) Filter Belts 3) Rollers 4) Poly slide plate assembly 5) Bearing assemblies 6) Steering valve/paddle assemblies 7) Adjustable stainless steel washboxes 8) Upper washbox mounting brackets 9) Lower washbox mounting brackets 10) Dual shaft mount drive units with roller assemblies 11) Retrofit hydraulic lid assembly 12) Gravity section cross members 13) Press mount electrical system 14) Stainless Steel drain pans/piping 15) Retrofit feed chute assembly 16) Wedge plate assembly 17) Tension yoke bearings 18) Scraper blades 19) Rubber seals 20) Wedge scraper blade 21) Chicane blades 22) Grid wear bars 23) Reversal roller guard flap 24) Control panel

b. Refurbishment items: 1) Regalvanize/paint main frame and all carbon steel parts 2) Sandblast all stainless steel parts 3) Washtubes with new inner brushes 4) Washtubes with new spray nozzles

B. The equipment to be furnished under this section of the Specifications also includes replacing one (1) 2.0-meter belt filter press (BF-2) and all ancillary items in the Dewatering Building. The components associated with the press shall include, but not be limited to, the following items:

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1. Sludge conditioning system. 2. Structural main frame. 3. Gravity drainage section. 4. Pressure section. 5. Rollers. 6. Bearings. 7. Belt wash system. 8. Belt alignment system. 9. Belt tensioning system.

10. Belt tensioning drive system. 11. Belt drive system. 12. Filter belts. 13. Discharge blades. 14. Drainage pans. 15. Control system. 16. All instrumentation and contacts necessary for a complete operating system.

C. SCADA: Manufacturer shall provide control panel OIT screens for the System Integrator to copy for the SCADA HMI screens. Manufacturer shall provide addresses for signals as requested by System Integrator to communicate with SCADA system.


A. Manufacturer Qualifications: 1. All equipment shall be the product of a manufacturer having at least twenty (20)

similar system installations in the United States of the type proposed, each with a minimum of five (5) years of satisfactory service.


B. Manufacturer's installation report is required prior to final acceptance.

C. All equipment of each type specified in this section shall be supplied by a single manufacturer.

D. Manufacturer shall maintain a complete stock of spare parts commonly needed for the equipment specified at a location within the U.S. or spare parts must be made available within a 48-hour period.

E. All equipment shall have a stainless steel manufacturer's nameplate securely affixed in a conspicuous place on the equipment showing the ratings, serial number, model number, manufacturer and other pertinent nameplate data.

F. The belt filter press Equipment Manufacturer shall furnish and be responsible for the complete system, including the belt filter press, with all ancillary equipment and controls to provide a working system as described herein.

G. The manufacturer of each type of equipment specified herein shall perform a complete testing procedure on the assembled equipment in the field to be supplied. A report on the field test results is required prior to acceptance of the equipment.

1.4 SUBMITTALS

A. Submittals shall be prepared and submitted in accordance with Section 01300 “Project Documentation”.

B. The following submittals are required at a minimum, in addition to any other applicable requirements of Section 01300 “Project Documentation”. 1. Shop drawings specific to project and applicable product data bound neatly in a single

package. The following information shall be included as a minimum: a. Manufacturer and model number of equipment.

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b. Layout drawings including all proposed system components with dimensions, clearances required and sizes indicated, and total operating weights of the product (sludge, water, equipment, etc., wet and dry).

c. Detailed specifications and data describing the materials of construction. d. Complete information on electric motors furnished including make and type of

motor, brake horsepower and locked rotor current at full voltage. e. Complete electrical and instrumentation wiring diagrams and data on controls

to be furnished. f. Performance capability data. g. Calculations of dewatering areas and bearing life for each component type.

2. Location of nearest stocking distributor of spare parts. 3. Complete operation and maintenance data for all equipment and controls in

accordance with Section 01300. 4. Start-up and test schedule with test procedures. 5. Equipment installation report with field test data and test records in accordance with

Section 01300. 6. Warranties and service agreements. 7. Installed Performance Test procedure with parameters necessary for a successful

test. 8. Storage requirements for all equipment (to be provided with first submittals).

C. Any other information necessary for the ENGINEER to determine compliance with the specifications.

D. All deviations from these Bidding Documents shall be clearly identified and submitted for review by the ENGINEER. Partial or incomplete submittals will not be received by the ENGINEER.


A. Delivery, storage, and handling shall be in full accordance with manufacturer's instructions.

1.6 SPECIAL EQUIPMENT WARRANTY

A. The equipment manufacturer shall jointly warrant to the OWNER and to the CONTRACTOR that all equipment, including all components of the complete assembly furnished by it hereunder, complies in all respects with the design and specifications of these Documents and contains no defects of material or workmanship. In the event of failure of any part or parts of the equipment during the warranty period due to defects of design, materials, or workmanship, the affected part or parts shall be replaced promptly upon notice by the OWNER. All replacement parts shall be furnished, delivered, and installed at the expense of the equipment manufacturer.

B. The warranty period shall be two years following acceptance of the equipment by the OWNER. The warranty period shall be exclusive of use of the equipment in installation, testing, adjusting, etc., during construction prior to acceptance, or of the time in storage after delivery and prior to installation.

C. If the equipment does not meet the requirements of the Specifications, the equipment manufacturer shall correct or service the equipment at no additional cost to meet the specified requirements, where any such deficiencies are the responsibility of the equipment manufacturer. In the event the equipment is unable to meet the specified requirements within the warranty period, the equipment manufacturer shall refund an amount equal to the purchase price of new equipment that shall meet the specified requirements. The refund for purchase of new equipment shall not exceed the purchase order amount of the original equipment.

D. Warranties shall clearly state accuracies, operation limitations, tolerances, etc. that may affect performance of equipment as well as a description of what performance capabilities

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can be expected from equipment. In the event that these statements are ambiguous or not in conformity with the specified requirements, equipment will not be accepted.

E. The CONTRACTOR shall be responsible for insuring that the manufacturer’s special equipment warranty is not voided by acceptance of the terms of purchase agreements between the CONTRACTOR and the manufacturer. In all events, the CONTRACTOR shall be held ultimately responsible for enforcement of the requirements of this warranty at his expense.

F. Payment for equipment as “Materials-On-Hand” will not be made until an approved Special Equipment Warranty is received by the OWNER.

1.7 EQUIPMENT MANUFACTURER'S REPRESENTATIVE

A. The Belt Filter Press Equipment Manufacturer shall furnish a qualified field representative(s) for a minimum of one (2) trip for two (2) men for five (10) working days to assist the construction contractor with the disassembly of both existing belt press equipment.

B. The Belt Filter Press Equipment Manufacturer shall furnish a qualified field representative(s) for a minimum of two (2) trips for two (2) men for ten (10) working days to assist the construction contractor with the reassembly the belt press equipment.

C. The Belt Filter Press Equipment Manufacturer shall furnish a qualified field representative for a minimum of two (2) trips and eight (8) working days to inspect all equipment specified herein after installation, to assist in troubleshooting, to advise the construction Contractor and OWNER during start-up and testing, and for performance testing. One (1) additional trip and two (2) working days shall also be provided for operator training and to instruct the OWNER's personnel in routine maintenance and troubleshooting procedures. Two (2) follow-up inspections, totaling two (2) working days shall also be included.

D. Working days shall exclude travel time and shall consist of eight (8) working hours spent at the plant site.

E. All instructions provided shall consist of: 1. Field videotaping of all new equipment and facilities while the EQUIPMENT

MANUFACTURER’s representative explains the purpose of the equipment and demonstrates its proper maintenance and operation.

2. Classroom presentation of the video under the supervision of the EQUIPMENT MANUFACTURER’s representative.

3. Field "hands-on" instruction by the EQUIPMENT MANUFACTURER’s representative.

F. The OWNER will provide the video camera equipment and operator. The instruction and training program is to be submitted to the ENGINEER for his approval prior to its initiation.

G. The equipment manufacturer's representative shall conduct follow-up inspections at the end of six (6) months of operation after final acceptance of equipment and ten (10) months of operation after final acceptance of equipment. A report shall be submitted after each inspection to the OWNER giving the details of actual operation, maintenance, and care of the equipment and suggested revisions and improvements. At the ten (10) month inspection, the equipment shall be carefully examined by the representative and a list of any equipment showing defects in material and manufacturing workmanship shall be prepared. Any equipment listed as defective shall be replaced or repaired and shall be furnished by the Equipment Manufacturer.

H. The Equipment Manufacturer shall coordinate with the construction contractor on the scheduling of such installation assistance, training and start-up assistance with OWNER's personnel. Troubleshooting, start-up, and testing activities associated with the polymer feed system shall be carried out concurrently with these same activities for the Belt Filter Press. It is the responsibility of the Belt Filter Press Equipment Manufacturer to ensure that both of these equipment items function so as to meet the process design criteria specified herein. Belt filter press EQUIPMENT MANUFACTURER shall be responsible for obtaining

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assistance from polymer feed system equipment manufacturer as required to ensure a satisfactorily installed and operating system.

PART 2 - PRODUCTS


A. All equipment including controls specified herein shall be specifically designed for the separation of solids from municipal wastewater treatment plant sludge and the environment encountered in this installation. The environment will be moist and corrosive, and will exhibit hydrogen sulfide and other corrosive gases encountered in municipal wastewater treatment plants. The sludge may contain abrasive and stringy materials. These and other conditions generally characteristic of wastewater treatment plant sludge are not considered abusive or abnormal with respect to equipment warranty provisions.

B. Equipment shall be designed and capable of either continuous or intermittent operation. This specification covers certain required features of the equipment, but does not purport to cover all details entering into its design.

C. All equipment specified in this section shall be furnished by the manufacturer of the belt filter press except as otherwise indicated. This does not require that all equipment be manufactured by a single manufacturer, but does require that the manufacturer of the belt filter press shall be responsible for the satisfactory operation of the dewatering equipment and the associated equipment listed herein.

D. The Equipment Manufacturer shall guarantee the belt filter press and polymer system as set forth in this Section.

E. EQUIPMENT MANUFACTURER shall be responsible for testing sludge, selecting polymer to be used, and obtaining and paying for polymer for use in start-up, and for performance test.

2.2 PROCESS DESIGN CRITERIA

A. The belt filter press shall be designed to meet the following design criteria for dewatering sludge described as an aerobic secondary municipal domestic wastewater treatment plant sludge: 1. Feed solids in slurry: Currently <1%; Expected when thickening process included in a

couple of years, 2-3% (expected range). 2. Hydraulic loading rate: 50 - 100 gallons per minute per meter. 3. Minimum solids handling capacity: 1000 pounds dry solids per hour per meter. 4. Minimum solids in cake discharge: 17% (Samples of the sludge may be obtained at

the WWTP.) 5. Minimum solids capture rate: 95%. 6. Maximum polymer neat consumption: 15.0 pounds per ton of dry solids.

2.3 DESCRIPTION OF BELT FILTER PRESS SYSTEM

A. Prior to dewatering, feed sludge and polymer are mixed in the inlet piping through the use of an in-line mixer. Diluted polymer shall be introduced to the feed sludge piping through a UHMW HDPE injection ring located upstream of the mixer's inlet flange. The mixer shall impart sufficient turbulence to the sludge and polymer to produce thorough mixing and, subsequently, efficient flocculation of the feed sludge with a minimum of polymer addition.

B. The flocculated sludge shall pass from the mixer through the remainder of the feed piping and into the distribution headbox of the belt press. The headbox, or inlet distributor, shall evenly distribute the flocculated sludge over the effective dewatering width of the moving filter belt. The headbox shall be easily accessible for operating, viewing, cleaning, and adjusting, and shall prevent sludge from leaking or spilling.

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C. The belt filter press shall be designed to concentrate and dewater sludge by means of two (2) belts, arranged to perform the conveying, pressing and dewatering in three (3) zones of logical sequence: 1) gravity drainage zone, 2) wedge pressure zone, and 3) shear-pressure zone. The cumulative areas of these three dewatering zones shall be a minimum of 273 square feet.

D. In the gravity zone, the belt shall be supported by a grid which shall break the surface tension to facilitate gravity drainage. A series of rows of vertical sludge agitators shall also be provided to create paths for water drainage and to provide new available surfaces in the sludge to enhance dewatering.

E. Sludge shall be contained within the gravity zone by a specially designed seal barrier to prevent leakage and minimize seal and belt wear. Inclined gravity zone or auxiliary vacuum applied to the gravity zone shall not be acceptable. The gravity zone shall contain a minimum of 93 square feet of filtration area.

F. The second section will provide a low pressure zone where the upper belt will then converge with the lower belt at a specified dewatering angle and generate continuously increasing pressure. The wedge or low-pressure zone shall provide a minimum of 59 square feet of filtration area. The wedge angle shall be set by the manufacturer but shall also be adjustable by the press operator to facilitate optimizing press performance. Sludge shall be contained in the low pressure zone by wedges or splash guards, and no leakage of sludge shall be permitted when the press is operating at its maximum capacity.

G. The shear or high-pressure zone shall provide a minimum of 120 square feet of filtration area and shall be of S-roll configuration to provide the maximum possible cake dryness. The upper and lower belt shall converge with the sludge cake between them and wrap around at least eight (8) S-rolls. The S-rolls shall be of progressively decreasing diameter in the running direction of the machine. With belt tension constant the sludge shall undergo an incremental increase as the belts wrap around each roll. Both belts shall be in contact with the sludge for a minimum length of 4.5 feet.

2.4 BELT FILTER PRESS ASSEMBLY

For the refurbished belt press, the belt filter press equipment shall meet the original specification for each press. Manufacturer shall note items that have been upgraded in shop drawing.

For the belt filter press replacement, the new system shall be a complete dewatering unit consisting of the main components listed hereinafter.

A. SLUDGE CONDITIONING SYSTEM 1. A sludge conditioning system, designed to efficiently mix polymer with the sludge and

to adequately condition the sludge, for optimum dewatering shall be provided. The sludge conditioning system shall be mounted in the piping upstream of the press and shall consist of an in-line adjustable, non-clog, static mixer constructed of stainless steel with a variable orifice and a vortex polymer injection ring.

2. The sludge conditioning system shall be capable of providing the following performance: a. The polymer and sludge must be instantly mixed (less than 1.0 second at

60 GPM). b. Mixing energy must be independently adjustable during operation. c. Flocculation time must be independently adjustable, by the alternate placement

of the injection ring and mixer at a minimum of two locations in the sludge feed piping.

3. The sludge conditioning system shall meet the following mechanical specifications: a. The in-line mixer shall have a flanged, cast housing, an adjustable orifice plate

with shaft and O-ring seal connected to an externally mounted lever and counterweight and a removable side plate for inspection and cleaning. All of

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the above parts, except for the rubber O-ring and the hot-dipped, galvanized, cast iron counterweight, shall be constructed of Type 316 stainless steel.

b. The open throat area shall be fully adjustable downward and shall open automatically to prevent clogging.

c. The position of the counterweight on the externally mounted orifice plate lever shall be fully adjustable to allow for adjustment of the mixing energy, regardless of the mounting angle, while the unit is in operation.

d. Each injection ring shall have a minimum of four (4) inlets (spaced evenly around the ring's circumference) and shall be constructed of UHMWPE. EQUIPMENT MANUFACTURER shall furnish a polymer distribution manifold and tubing to distribute the polymer from a single pipe to the four inlets on the ring.

B. STRUCTURAL MAIN FRAME 1. The structural main frame shall be fabricated of steel members conforming to ASTM

Standard Specifications for Structural Steel, Designation A36-77a, into a rigid structure, adequately braced to withstand intended loads without excessive vibration or deflection.

2. Structural members shall be structural channels or beams with minimum flange thickness of 1/2-inch, a minimum web thickness of 5/16-inch and a minimum moment of inertia of 25.4 inches to the fourth power. The frame for each belt filter press shall have a minimum safety factor under maximum load of 5 with respect to the design yield strength of the member.

3. Maximum load shall be based on the summation of all forces applied to the frame including roller mass forces and tension forces (forces exerted by the tension on the belts from the belt tensioning devices). Tension forces shall include, but not be limited to, a belt tension of 50 P.L.I. which is equivalent to 200 pounds per inch of belt width in the shear pressure section and drive torque. Calculations shall be provided to document from stresses during lifting.

4. The framework shall be of welded and/or bolted construction. All welding shall conform with the American Welding Society Structural Welding Code. All bolts shall be 316 stainless steel.

5. The frame surface shall be prepared by the pickling method or shall be blasted according to SSPC-SP-10. Then it shall be hot-dipped galvanized with 2 ounces of zinc per square foot of metal surface (4-7 mils) in accordance with ASTM A123. This shall be followed by a primer for galvanized surfaces (1.5 dry film thickness), followed by two coats of two-component polyamide epoxy paint minimum (3 mils dry film thickness each). All other steel components, other than stainless steel, shall be abrasion-blasted to the same specification and covered with a two component polyamide epoxy lead free primer (1-1/2 mils dry film thickness) followed by a heavy duty polyamide, two component lead free high gloss epoxy finish (3 mils dry film thickness).

6. The unit shall be designed for installation on a prepared concrete foundation and secured with Type 316 stainless steel anchor bolts. Anchor bolts shall be sized and provided by the EQUIPMENT MANUFACTURER. Bolts and templates shall be shipped by EQUIPMENT MANUFACTURER either upon OWNER's request or as planned by the EQUIPMENT MANUFACTURER, whichever occurs first. Permanent lifting lugs shall be provided as necessary to allow installation and removal of the belt filter press.

7. The construction shall allow easy access and visual inspection of all internal components.

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C. GRAVITY DRAINAGE SECTION 1. A gravity drainage section shall be provided to accept sludge from the sludge

conditioning system. The gravity drainage section shall contain an inlet distributor to evenly distribute the conditioned sludge over the effective width of the moving filter belt.

2. The materials in contact with the sludge in the distribution area shall be Type 316 stainless steel, with a minimum thickness of 14 gauge.

3. The conditioned sludge shall be contained on the belt with Type 316 stainless steel barriers, 14 gauge minimum thickness, and equipped with replaceable rubber seals to prevent leakage.

4. The filter belt, while in the gravity drainage section, shall be supported by a Type 316 stainless steel grid, fitted with high density polyethylene wiper bars, spaced at a maximum of 2-1/2 inches. The belt support grid shall be a minimum of 2 inches wider than the belt and designed so as to reduce belt wear. Filtration in this section shall be minimum 93 ft2, measured on one belt considering the width between seals times the total length of the gravity zone.

5. The gravity drainage section shall be furnished with chicanes (agitators) to adequately furrow the conditioned sludge to facilitate drainage. The chicanes shall be constructed of high density polyethylene or 316 stainless steel with Type 316 stainless steel holders and designed so as to reduce belt wear. Each row of chicanes shall be provided with a single lifting handle, designed to remove the entire row of chicanes at least 6 inches from the belt, out of the sludge flow, to facilitate cleaning. Chicanes shall be designed to be individually moved laterally or horizontally. There shall be a minimum of ten (10) rows of chicanes and a minimum total of 80. Individual chicanes shall be spaced evenly laterally across the filter belt. The complete plow assembly shall be lifted from the filter belt for cleaning purposes by operating a single valve located at the belt press hydraulic control panel.

6. Mounting hardware for chicanes shall be Type 316 stainless steel. All fasteners shall be Type 316 stainless steel.

D. PRESSURE SECTION 1. A pressure section, following the gravity drainage section shall be provided and shall

consist of two stages: The increasing pressure zone (wedge zone) and the shear pressure zone.

2. The first stage of the pressure section shall be the increasing pressure zone, where the upper and lower belts gradually converge and where the sludge cake is prepared for the shear pressure zone by generating continuously increasing pressure on the sludge as it travels through the zone. For process flexibility, the amount of pressure exerted on the sludge and the rate at which the increasing pressure is applied in the increasing pressure zone shall be independently adjustable. These adjustments shall be capable of being performed without affecting the tension on the belts in the shear pressure zone. The belt in the increasing pressure zone shall be supported by polyethylene wear bars, which are supported by 316 stainless steel grid system as described in the gravity section. All parts which may be contacted by polymer or sludge shall be 316 stainless steel.

3. The second stage of the pressure section shall be the shear pressure zone consisting of a minimum of eight (8) rollers, arranged to provide an "S" shaped pattern of belt travel. This first roller in this zone shall be a stainless steel perforated roller. The sludge shall be subjected to an incremental increase in pressure, without an increase in belt tension, as it travels over decreasing diameter rollers toward the cake discharge.

4. The pressure zone configuration shall be such that the filtrate is removed from the sludge cake without rewetting of the downstream cake.

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E. ROLLERS 1. All Solid Rollers shall be constructed using one-piece forge shafts and end

plates. The forged stub shaft unit shall eliminate all welding of the roller shafts in the region of highest stress where the shafts join with the end plates. Welded up constructions of round bar and flat plates that create built in stresses and stress concentrations will not be considered equal to this specification. The forged stub shaft unit shall be welded to the roller shell with a machine-applied weld using the submerged arc process. The weld depth shall be equal to the wall thickness of the roller shell. The roller shall be machined so that the total indicated runout of the shell relative to the journals is 0.010 inch maximum. Total surface machining is required to provide a smooth surface for the coating of thermoplastic nylon or to prepare the roller for cladding.

2. The perforated roller, which is the first roller in the pressure section, is designed to allow water to escape out both ends. It shall be constructed with a solid through shaft and at least five (5) radial vanes to support the perforated shell.

3. Materials: a. The forged stub shaft unit shall be made of ASTM A572 Grade 50 Type 2 or

equal. The roller shells may be ASTM A53 or equal. The perforated roller shall have a solid shaft of cold drawn carbon steel, AISC 8620 and the shell and radial vanes shall be ASTM A36 or equal, or stainless steels may be substituted on special order.

b. Drive rollers shall be coated up to the point of insertion into the bearings by a 1/4-inch minimum thickness of Buna-N rubber. Solid and perforated rollers shall be coated with a 30-mil minimum thickness of thermoplastic nylon. See detail spec for these coatings in Section 2.01.

c. Solid rollers may also be clad with 304 or 316 stainless steel. The cladding will be welded to the fully machined roller entirely covering the roller up to the point of insertion into the bearings. Welded stainless steel shafts in lieu of the forging are not acceptable for this application due to the lower strength and higher stress.

4. Dimensions: a. All solid roller shells shall have a mill spec minimum wall thickness of 1/2

inch. Heavier walls shall be used where required to meet the maximum stress and deflection limits. The roller bearing journals shall be turned to 75 mm to accept direct mounted 75 mm bore bearings. The minimum thickness of the forged flange that forms the end plates shall be one (1) inch.

b. The perforated roller shall have punched holes of 1 1/4 inch diameter minimum to prevent bridging of solid material. The punched shell shall be rolled with the smooth side out. The shell shall be a minimum 1/4-inch thick.

5. Stress and Deflection: a. The rollers shall be analyzed using finite element stress analyses. Certified

calculations, showing the maximum stress to be less than 1/5 the yield strength of the material and the maximum deflection at mid span to be less than 0.050 inch shall be submitted as set forth in the contract documents. The standard load case for the pressure rollers shall be a distributed load in the belt contact area equivalent to 50-pli belt tension, weight loading and drive torque. The standard load case for the other rollers shall be a distributed load in the belt contact area equivalent to 50-pli belt tension and weight loading.

F. BEARINGS 1. All rollers shall be supported by greaseable type, high capacity design roller bearings,

in sealed, splash proof, horizontal split case pillow block housings. The bearings shall be direct mounted on the shaft with a shrink fit backed by a retaining snap ring.

2. Bearings supporting the steering rollers shall be non-self-aligning cylindrical roller bearings in pivot mounted pillow block housings.

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3. All other rollers shall be supported by self-aligning Type “E” spherical roller bearings with metallic cages, (plastic cages in spherical roller bearings are not acceptable) mounted in fixed pillow block housings.

4. Bearings supporting all the rollers except the steering rollers shall be 75mm bore double row spherical bearings (type E construction) AFBMA size number 2215 with a dynamic radial capacity of 41,500 lb. Bearings supporting the steering rollers shall be 75mm bore single row cylindrical roller bearings AFBMA size number 2215 with a dynamic radial capacity of 36,500 lb.

5. Bearing housings shall be cast iron with two mounting bolts and four cap bolts. The outer side of the housing shall be solid, without end caps or filler plugs. The housings shall be designed with an integrally cast water trough which, when shrouded by a shaft mounted water flinger, shall divert water from the bearing seal area. The housings shall be cleaned, iron phosphate, and coated with nylon to a thickness of 8-12 mil.

6. The bearing seal in the pillow block housing shall be of nonmetallic construction with a carrier/flinger, which rotates with the roller shaft. A static sealing arrangement between the carrier/flinger and the shaft shall be a triple rubber seal, constructed in a manner that prevents relative rotation between the seal and the shaft. A dynamic sealing arrangement between the carrier/flinger and the bearing housing shall consist of a primary dynamic contact seal of ozone resistant rubber which shall seal by rotational contact with a machined housing surface. A secondary dynamic seal shall be a labyrinth seal between the carrier/flinger and the bearing housing which utilizes a nonmetallic retaining ring to hold the seal assembly in position within the housing.

7. Bearing lubrication shall be performed through stainless steel grease fittings mounted on each bearing housing. All bearings shall be outboard (externally mounted) and shall be greaseable while the unit is in operation. Lubrication shall not be required more often than once every six months.

8. L-10 life shall be no less than 360,000 hours.

G. BELT WASH SYSTEM 1. The belt filter press shall be equipped with individual belt wash stations for both the

upper and lower belts. Each station shall consist of a spray pipe, fitted with spray nozzles, contained within a fabricated housing which encapsulates a section of each belt. The housing and nozzle assembly shall be readily removable. EQUIPMENT MANUFACTURER shall furnish 1.5-inch motor-operated bronze valve for washwater supply pipe and incorporate valve opening and closing with start-up and shutdown.

2. Nozzle spacing and spray pattern shall be such that the sprays from adjacent nozzles overlap one another at the belt surface. The spray pipe and nozzles shall be ASTM A312 Type 316L stainless steel construction. Individual nozzles shall be replaceable.

3. The housing shall be fabricated from ASTM A 167 Type 316L stainless steel with a minimum thickness of 14 gauge. The housing shall be sealed against the belt with rubber seals. The seals shall be replaceable without disassembly of the wash station.

4. Each belt wash station shall be furnished with an external handwheel which is mounted to a stainless steel cleaning brush located inside the spray pipe. One full turn of the handwheel shall cause the brush bristles to enter each spray nozzle, and dislodge any solid particles which have accumulated, open a valve and allow the solids particles to be flushed into the drainage system.

5. Belt wash stations shall be of the type manufactured by Appleton Manufacturing, Menasha Corporation, Menasha, Wisconsin, the Heinrich Stamm Company, Worms Am Rhein, West Germany, or approved equivalent.

6. Each belt wash station shall be positioned such that the washing is performed after the cake has been discharged from the belt. The belt wash station shall extend over the full width of the filter belt by a minimum of two (2) inches. The belt shall be cleaned by the belt wash such that blinding will not occur.

7. The belt wash system for each belt filter press shall be suitable for use with plant effluent water supplied at a minimum pressure of 90 psig and shall be designed to

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operate on a maximum flow of 100 gpm. Each belt wash system shall be furnished with a globe valve for throttling and shall be mounted on the belt filter press frame.

H. BELT ALIGNMENT SYSTEM 1. Each belt shall be provided with an automatic belt alignment system to assure proper

alignment of both belts at all times. The alignment system shall be hydraulically actuated.

2. The belt alignment system shall be provided with sensing devices which ride on the edge of the belts to detect their position. The device shall operate a pilot valve which in turn affects the position of an actuator connected to a pivoted belt alignment roller. The pilot valves for steering shall be 316 stainless steel. The pivoting action of the belt alignment roller shall cause this roller to skew from its transverse position to guide the belts centrally along their path.

3. The alignment systems shall function as a continuous automatic belt guidance system and shall be an integral part of the press. The alignment system shall operate with smooth and slow motions resulting in a minimum of belt travel from side to side.

4. Back-up limit switches for the belt alignment system shall be provided on the machine with sufficient contacts to de-energize all drives and sound an audible and visual alarm in case of belt over-travel.

I. BELT TENSIONING SYSTEM 1. The belt tensioning system shall be hydraulically actuated. The design of the

tensioning system shall be such that dewatering pressure is directly proportional to belt tension and that adjustments in tension shall result in immediate changes in dewatering pressure.

2. The belt tensioning system control station shall be calibrated to provide an indication of actual dewatering pressure in pounds per linear inch at various readings of hydraulic. Normal operating limits shall be indicated on the face of the station. Actual dewatering pressure, as indicated by the setpoint selected on the control station, shall be maintained automatically despite process changes.

3. The tensioning system shall have two hydraulic cylinders for each belt, directly connected to a rigid tensioning yoke, to provide absolute parallel tension across the entire width of the belt. The tension force shall be constant over the full range of the cylinder.

J. BELT TENSIONING AND ALIGNMENT DRIVE SYSTEM 1. The belt filter press shall be provided with a belt tensioning and alignment system

drive unit. The drive unit shall be a 1 HP hydraulic type power system. 2. Hydraulic power systems shall include pump, Type 316 stainless steel reservoir, oil

cooler, filters, valves, gauges, Type 316 stainless steel hydraulic tubing from the drive to and from the belt filter press, switches, and controls. The pump, motor, reservoir, oil filter, and valves shall be mounted directly to the belt press frame to minimize excess piping runs, fittings, and hoses. The hydraulic power system shall be sized and provided by the press manufacturer, and all system components shall be the manufacturer's responsibility.

3. Power units shall be capable of delivering a maximum pressure to the belt of 70 P.L.I. 4. Hydraulic cylinders shall have a non-corrosive body and 316 stainless steel hardware

and cylinder rod. The cylinder rod shall be solid stainless with a hardened polished seal contact surface.

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K. BELT DRIVE 1. Drives shall be capable of variable frequency speed operation controlled from either

the main control panel or at the smaller, remote panel specified hereinafter, depending on the position of a local/remote switch mounted on the belt press control panel. Drives shall be furnished with provisions for use on a 480 volt, 60 Hz, 3-phase power supply, with overload and short-circuit protection provided. Drive rollers shall be coupled together by the use of gears.

2. For dual drive systems, input power to each of two drive roller shafts is supplied through two A.C., high efficiency motor-driven, shaft-mounted, torque arm retained, Eurodrive helical-bevel gear reducers. Roller rotational speed is controlled through variation in motor frequency which is regulated by the operator via a potentiometer input to a variable frequency drive controller. Rotational timing of the two drive rollers, which is necessary for proper operation, is achieved by the use of a single variable frequency drive which controls both motors wired in parallel to each other, accomplishing a speed match. This drive system will be comprised of the components listed below:

Reducer Data Quantity per machine: 2 Descriptions: Helical-bevel right angle shaft

mounted gear reducer. A.C. motor mounting to be C face.

Belt speed: 0-5.0 meters per minute Service factor in this application: 1.40 Service rating: Up to and including AGMA Class III Motor Data Quantity per machine: 1 Horsepower: 3 Power requirement: 480-volt, 3-phase, 60-hertz Maximum speed: 1800 rpm NEMA design: B Ambient temperature: 40°C Insulation class: F Full load amps: 240-volt at 9.6 amps and 480-volt at

4.8 amps Efficiency: 88.5% Service factor: 1.15 Time rating: Continuous Enclosure: TEFC Motors shall comply with Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below.”

L. DEWATERING BELTS 1. The press shall incorporate the use of two (2) dewatering belts. Belts shall be

seamed and fabricated of monofilament polyester, wear-resistant plastic materials, or combination monofilament polyester and stainless steel material. The mesh design shall be selected for optimum dewatering of the sludge to be processed with minimum blinding of the filter belt.

2. Each belt and connecting splice shall be designed for a minimum tensile strength equal to five times the normal maximum dynamic tension to which the belt shall be subjected. The splice shall be designed to fail before the belt and shall be constructed of Type 316 stainless steel.

3. Belts shall have a width as specified and shall have a minimum life of 2,000 hours continuous operation at the rated design conditions.

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4. Belts shall be designed for ease of replacement with a minimum of belt filter press down time.

M. DISCHARGE BLADES 1. Discharge, or doctor, blades shall be provided to scrape dewatered sludge from the

belt at the final discharge rollers. The blades shall be of ultra high molecular weight polyethylene construction and shall be readily removable. Blades shall be designed to wear before the filter belts.

2. The blades shall be affixed to a hot dip galvanized counterweight assembly with a Type 316 stainless steel holder. The blades and assembly shall be fabricated with sufficient stiffness so that the blades do not warp, distort or bow under normal service conditions.

3. The assembly shall be equipped with devices to enable the blades to be quickly released and locked in position away from contact with the belts for cleaning and maintenance.

N. DRAINAGE PANS 1. Drainage pans shall be supplied as necessary to contain all filtrate and washwater

within the belt filter press without splashing and to prevent rewetting of downstream cake. Filtrate and washwater pans shall be constructed of minimum 14-gauge A 167 Type 316L stainless steel suitable for the intended service. All drainage piping shall be Schedule 40 PVC and shall be furnished adequately sized for the intended service and rigidly attached to the press frame. All fasteners shall be Type 316 stainless steel. Drain connection shall be self-venting to prevent overflow. Flushing connections or similar provisions shall be provided for easy access during cleaning. Drainage pans shall be located such that the moving belts do not come into contact with the pans under any conditions.

O. ELECTRICAL CONTROL PANEL 1. The belt filter press shall be supplied with a NEMA 4X, 316 stainless steel, free-

standing single door enclosure with through door-operated main disconnect. Control power transformer, control relays, and alarm relays shall be provided for complete manual operation of belt filter press system. Door mounted components consist of NEMA 4X illuminated start and non-illuminated stop pushbuttons, selector switches, pilot lights and an alarm horn and light. Entire operation of the belt filter press system shall be displayed by indicator lights and digital meters.

2. The panel shall operate using a 480-VAC, 3-phase, 60-Hertz power supply. Refer to Section 16486 “Mechanical Equipment Manufacturer's Provided Control Panels (MEMs)” for the construction requirements of each Control Panel.

3. The panel shall be completely wired and tested, with terminal strips for external wiring connections. The panel shall contain a variable frequency drive controller for main belt drive and motor starters for belt tensioning drives.

4. The Belt Press Control Panel shall include the following components: a. Indication push to test transformer lights and indicating meters for:

1) Machine E-stop 2) Belt Limit Alarm 3) Belt VFD Failure 4) Loss of Cake Alarm 5) Air Loss Alarm 6) System Control Power On/Off Light 7) Belt Press HOA 8) Pre-Wet Alarm 9) Polymer Pump Failure Alarm 10) Sludge Pump Failure Alarm 11) Low Water Pressure Alarm 12) Sludge Conveyor Fail Alarm 13) Push to Test Pushbutton 14) Alarm Silence Pushbutton

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15) Wash Down Status 16) SSCP Running 17) SSCP Ready 18) Belt Tension Load Pushbutton 19) Belt Tension Unload Pushbutton 20) Washwater Stop Pushbutton 21) Sludge Conveyor Run 22) Alarm Reset Pushbutton 23) SSCP Fault Alarm 24) Belt Press Start and Stop Pushbuttons 25) Sludge Pump Start and Stop Pushbuttons 26) Polymer Pump Start and Stop Pushbuttons 27) Belt Speed Indicator 28) Sludge Flow Indicator 29) Polymer Flow Indicator 30) Increase/Decrease Belt Speed Pushbuttons 31) Increase/Decrease Sludge Flow Pushbuttons 32) Increase/Decrease Polymer Flow Pushbuttons

b. Automatic start-up and shut-down controls: 1) Controls for automatic start-up and shut-down of the belt filter press shall

be provided as follows: a) Start-up Sequence

• Energize water Booster Pump and open washwater solenoid valve.

• Energize belt tensioning drive. • Energize belt drive. • Energize belt conveyor (utilize existing controller). • Energize lime feed system (utilize existing controller). • Energize Polymer Feed Pump. • Energize Belt Press Feed Pump.

b) Shutdown Sequence • De-energize belt press feed pump. • De-energize polymer feed pump. • De-energize belt drive. • De-energize belt tensioning drive. • De-energize belt conveyor (utilize existing controller). • De-energize lime feed system (utilize existing controller). • De-energize washwater booster pump and close washwater

solenoid valve. 2) Controls for automatic start-up and shut-down shall be provided with

timed runout for each step of both start-up and shutdown sequences. Coordinate timing with OWNER/operators at start-up.

c. Interlocks shall be provided such that belt press shutdown sequence is initialized due to any of the alarm conditions in paragraph 2 above. Control panel shall provide adjustable time delays of at least 0 to 30 minutes for sludge pump and water booster pump restart. A set of contacts wired to the terminal block shall also be provided for remote monitoring of status and malfunction of all Belt Filter Press equipment. Signals shall be provided for remote monitoring of all analog signals.

d. Other control panel requirements: 1) Condensation heater. 2) Interior light. 3) 120 volt receptacle. 4) Two (2) additional sets of contacts for common alarm shall be provided.

One (1) set of contacts for remote alarm light and horn on top of the

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Dewatering Building, and one (1) set of contacts for common alarm reporting in the Control Room of the Operations Building.

5) All status and alarm conditions at the control panel shall be capable of being transmitted to the plant computer system.

e. The Bidding Documents contain the requirements for system functionality, however, it is the responsibility of the EQUIPMENT MANUFACTURER to determine and furnish all programming necessary for a complete, operable system.

P. LOCAL CONTROL PANEL 1. Each belt press shall be supplied with a NEMA 4X, 316 stainless steel handrail mount,

single door enclosure. The panel shall be completely wired and tested, with strips for external wiring connections. The panel shall contain controls for varying the speed of the belt, the pumping rate of the belt press feed pump selected and the pumping rate of the polymer feed pump selected. Sludge feed rates and polymer feed rates and belt drive speed shall be displayed on the panel face as well. Indicating lights shall be provided beside each control potentiometer which indicates when local control is enabled. All controls shall be door mounted, with appropriate name plates.

2. Refer to Section 16486 Mechanical Manufacturer’s Provided Control Panels (MEMs), for the construction requirements of each Control Panel. All panels specified under this Section shall be submitted as a part of each associated mechanical equipment submittal.

3. The Belt Press Remote Control Panel shall include the following components: a. Booster Pump Start/Stop Pushbuttons b. Polymer Pump Start/Stop Pushbuttons c. Belt Press Start/Stop Pushbuttons d. Sludge Pump Start/Stop Pushbuttons e. Polymer Flow Indicator f. Belt Speed Indicator g. Sludge Flow Indicator h. Increase/Decrease Belt Speed Pushbuttons i. Increase/Decrease Sludge Flow Pushbuttons j. Increase/Decrease Polymer Flow Pushbuttons

Q. MACHINE WIRING 1. The belt filter press shall be supplied with the following NEMA 4X rated components:

Type 316 stainless steel junction box, emergency shutdown switches actuated by pull rope which completely encircles the press, and belt tracking limit switch.

2. Wire runs shall be in PVC coated conduit, non-metallic liquid tight flex and connectors, rigidly mounted to the press frame. All fasteners shall be Type 316 stainless steel.

2.5 TOOLS, SPARE PARTS, AND MAINTENANCE MATERIALS

A. Furnish and apply an initial supply of grease and oil as required by manufacturer.

2.6 ACCEPTABLE PRODUCTS

A. The acceptable equipment for the new belt filter press and the refurbished belt filter press shall be Ashbrook Klampress as manufactured by Alfa Laval, Inc. of Houston, Texas. The representative for Alfa Laval, Inc. for this area is Environmental Improvements, Inc., 517 North Kealy Drive, Lewisville, Texas 75057, Telephone No. (972) 436-2536. A not-to-exceed price letter is attached to the end of this section.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The belt filter press specified herein shall be installed on the second floor of the dewatering building, as indicated on the plans. The assembly of the unit must utilize a 6-ft x 12-ft floor

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opening to transport the equipment from the ground level to the second floor. The dewatering building bridge crane is no longer functional. Provide a temporary crane to lift equipment into the building.


A. The Equipment Manufacturer's representative shall: 1. Assist construction contractor with installation of all equipment furnished under these

Bidding Documents. 2. Approve installation, start-up equipment, and place equipment into operation. Check

units for excessive noise, vibration, alignment, general operation, etc. 3. Operate system to verify satisfactory performance of unit in presence of ENGINEER

and OWNER'S personnel. Provide certified field test reports as required by Section 01600.

4. Verify conformance to requirements. 5. Instruct plant personnel on care and maintenance, troubleshooting and operation. 6. Conduct Installed Performance Test in field per paragraph 2.1, and furnish report of

performance including parameters and settings used to achieve acceptable and optimum performance. Make revisions as necessary to optimize operation.

7. Revisit job site as often as necessary to correct deficiencies to satisfaction of ENGINEER.

END OF SECTION


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LIME STABILIZATION SYSTEM REHABILITATION F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 11\11151 LIME STABILIZATION .DOCX

SECTION 11151 LIME STABILIZATION SYSTEM REHABILITATION

PART 1 - GENERAL



1.2 SUMMARY

A. Furnish, install, start up, and test the following equipment for the rehabilitation of the lime stabilization sludge system. The existing system receives, stores and conveys granular (less than 3/8-inch diameter) quicklime with an average bulk density of 55 pounds per cubic foot. The rehabilitated system shall stabilize dewatered sludge to EPA Class B Standards. All equipment shall be factory tested prior to shipment. Equipment furnished shall include but not be limited to: 1. Lime silo components to be furnished to replace existing components:

a. Silo bottom cone mounting ring b. Bin activator c. 8-inch knife gate valve d. Bin Level Indicators (3) e. Storage silo fill pipe

2. Lime feed screw conveyor. 3. Sludge/lime mixer 4. Lime stabilized sludge discharge belt conveyor. 5. Covers and safety guards. 6. Control system. 7. Other necessary components, supports, hardware, electrical systems, controls, and

piping for a complete and operable system. 8. The CONTRACTOR shall furnish and be responsible for the electrical power and

instrumentation wiring and connections to all system equipment, including motors/drivers, conveyors, control panels and associated instrumentation and control devices.

9. SCADA: Manufacturer shall provide control panel OIT screens for the System Integrator to copy for the SCADA HMI screens. Manufacturer shall provide addresses for signals as requested by System Integrator to communicate with SCADA system.

B. All equipment specified in this Section shall be furnished by a single manufacturer. The manufacturer is responsible for the system design, assembly, testing, installation and performance. All equipment shall be factory tested prior to shipment. The CONTRACTOR’s responsibilities under the contract documents are not altered by this Section.

C. Related Sections: 1. Division 13 – Instrumentation 2. Division 16 – Electrical


A. The equipment manufacturer shall furnish a qualified field representative for a minimum of three (3) trips and six (6) working days, excluding travel, to inspect all equipment described herein after installation, to assist in troubleshooting, to advise the CONTRACTOR and OWNER during startup and testing, and to instruct OWNER's personnel in proper process procedures, routine maintenance, and troubleshooting procedures. The CONTRACTOR shall coordinate the scheduling of such training and startup assistance with OWNER's personnel.

B. Manufacturer's installation report is required prior to final acceptance.

C. All equipment of each type specified in this section shall be supplied by a single manufacturer.

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D. Manufacturer shall maintain a complete stock of spare parts commonly needed for the equipment specified at a location within Dallas, Denton, or Tarrant County, Texas or must be able to deliver spare parts within 48 hours of notification.

E. Each major equipment item shall have a stainless steel manufacturer's nameplate securely affixed in a conspicuous place on the equipment showing the ratings, serial number, model number, manufacturer and other pertinent nameplate data.

F. The manufacturer shall furnish and be responsible for the complete system including modifications to the existing Silo, Lime Feed Screw Conveyor, Sludge/Lime Mixer, Belt Conveyor and Controls as described further.

1.4 REFERENCES

A. Except as otherwise indicated, the current editions of the following apply to this Section: 1. Commercial Standards:

a. ASTM A 36 Specification for Structural Steel b. ASTM A 283 Specification for Low and Intermediate Tensile Strength

Carbon Steel Plates, Shapes and Bars c. AISI 8620 Alloy Steel, Hot Rolled and Cold Finished d. AWS D1.1 Structural Welding Code - Steel e. ASTM A48 Iron Castings f. SSPC-SPS No.6 Commercial Blast Cleaning g. ANSI/ASME B20.1 Safety Standards for Conveyors and Related Equipment

2. Manufacturer's Standards: a. Conveyor Equipment Manufacturers Association (CEMA) standards b. American Gear Manufacturers Association (AGMA) standards c. Institute of Electrical and Electronics Engineers (IEEE) standards d. National Electrical Manufacturer's Association (NEMA)

3. Where conflicts in specifications occur, most strict specification shall control. Conflict shall be brought to the attention of the ENGINEER for clarification.

1.5 SUBMITTALS

A. Submittals shall be prepared and submitted in accordance with Division 1. All deviations from contract documents shall be clearly identified and approved by the ENGINEER in writing.

B. The following submittals are required at a minimum in addition to the applicable requirements of Division 1: 1. Shop drawings specific to project and applicable product data bound neatly in a single

package. The following information shall be included as a minimum: a. Manufacturer and model number of equipment. b. Layout drawings including all proposed system components with dimensions,

clearances required and sizes indicated, and total weights of the product. c. Detailed specifications and data describing the materials of construction. d. Complete information on electric motors furnished including make and type of

motor, brake horsepower, and locked rotor current at full voltage per Division 16. e. Complete electrical and instrumentation wiring diagrams and data on controls to

be furnished. f. Performance capability data.

2. Location of nearest stocking distributor of spare parts. 3. Complete operation and maintenance data for all pumps and motors in accordance

with Division 1. 4. Startup and test schedule with test procedures. 5. Equipment installation report with field test data and test records. 6. Warranties and service agreements.

C. Any other information necessary for ENGINEER to determine compliance with the specifications.

D. All deviations from contract documents shall be clearly identified and submitted for review by ENGINEER.

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E. Partial or incomplete submittals will not be received by the ENGINEER.

1.6 EXPERIENCE REQUIREMENTS

A. All equipment shall be the product of a manufacturer having at least twenty (20) U.S. installations of the type being proposed, and have been in operation a minimum of 5 years of satisfactory service.

B. A list of similar installations shall be furnished upon request with the shop drawing submittal, including names and telephone numbers of contacts.

1.7 DELIVERY, STORAGE AND HANDLING

A. Delivery, storage and handling shall be in full accordance with manufacturer's instructions.

1.8 SPECIAL EQUIPMENT WARRANTY

A. The equipment manufacturer shall jointly warrant to the OWNER and to the CONTRACTOR that all equipment, including all components of the complete assembly furnished by it hereunder, complies in all respects with the design and specifications of these Documents and contains no defects of material or workmanship. In the event of failure of any part or parts of the equipment during the warranty period due to defects of design, materials, or workmanship, the affected part or parts shall be replaced promptly upon notice by the OWNER. All replacement parts shall be furnished, delivered, and installed at the expense of the equipment manufacturer.

B. The warranty period shall be two years following acceptance of the equipment by the OWNER. The warranty period shall be exclusive of use of the equipment in installation, testing, adjusting, etc., during construction prior to acceptance, or of the time in storage after delivery and prior to installation.

C. If the equipment does not meet the requirements of the Specifications, the equipment manufacturer shall correct or service the equipment at no additional cost to meet the specified requirements, where any such deficiencies are the responsibility of the equipment manufacturer. In the event the equipment is unable to meet the specified requirements within the warranty period, the equipment manufacturer shall refund an amount equal to the purchase price of new equipment that shall meet the specified requirements. The refund for purchase of new equipment shall not exceed the purchase order amount of the original equipment.

D. Warranties shall clearly state accuracies, operation limitations, tolerances, etc. that may affect performance of equipment as well as a description of what performance capabilities can be expected from equipment. In the event that these statements are ambiguous or not in conformity with the specified requirements, equipment will not be accepted.

E. The CONTRACTOR shall be responsible for insuring that the manufacturer’s special equipment warranty is not voided by acceptance of the terms of purchase agreements between the CONTRACTOR and the manufacturer. In all events, the CONTRACTOR shall be held ultimately responsible for enforcement of the requirements of this warranty at his expense.

F. Payment for equipment as “Materials-On-Hand” will not be made until an approved Special Equipment Warranty is received by the OWNER.

PART 2 - PRODUCTS

2.1 DESIGN CRITERIA

A. For the Bulk Lime Storage Silo replace the following items: 1. Silo bottom cone mounting ring 2. Bin activator 3. 8-inch control valve 4. Bin Level Indicators (3)

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B. Lime Feed Screw Conveyor. The Feed System shall be designed to transport granular quicklime at a rate of 250 to 2,500 pounds per hour. The manufacturer shall demonstrate by submission of calculations that the Feed System has the rated capacity

C. The Sludge/Lime Mixer shall be designed to produce a Class B end product. The sludge cake from the Belt Press shall be approximately 18 percent dry solids (minimum 60 pounds per cubic foot wet non-compacted weight). The design rate shall be 9.0 wet tons per hour of sludge cake and 2,500 pounds of lime per hour. The Lime Feeder shall be designed to convey a maximum of 2,500 pounds of lime per hour and shall have a VFD Drive with a turn-down ratio of 10:1.

D. The Discharge Belt Conveyor shall be designed to convey 12.0 wet tons of stabilized cake per hour. The Conveyor shall be able to discharge sludge in three locations as shown on the Drawings. It shall have two motorized plows that direct sludge to a side discharge and a weighted head pulley wiper that disengages when the plows are utilized.

E. The length for the Discharge Belt Conveyor shall meet the dimensional requirements shown on the Drawings. CONTRACTOR shall verify dimensions in the field. The CONTRACTOR and manufacturer shall coordinate the sludge/lime mixer and belt conveyor length per the Drawings. The OWNER will not pay extra for changes in conveyor and mixer lengths due to differences in manufacturer products.

2.2 LIME STORAGE SILO REPLACEMENT COMPONENTS

A. A mounting ring shall be provided to adapt the existing Silo cone to the new larger Bin Activator. The mounting ring shall be one piece that matches the existing 12 feet diameter silo cone, with welded commercial quality steel construction, meeting AWSD1.1. The CONTRACTOR shall field cut the Silo as shown on the drawings and field weld the mounting ring in place. 1. The cone exterior shall be sandblasted to SSPC-SP10 followed by two coats of

Tnemec 66-1211 at 3.0 to 5.0 mils DFT. The interior of the cone shall be mill finished; without sandblasting or painting.

B. Three bin level indicators shall be provided to replace existing indicators. Bin level indicators shall be operated on 120 volt single phase power. Indicators shall attach to existing flange openings and zinc plated fasteners.

C. Bin Activator and Appurtenances - The replacement bin activator equipment shall include all equipment and supports necessary for the operation of the bin activator. This includes, but is not limited to hangers, sleeves, gyrator, motor, knife gate, flexible connections and appurtenances required for a complete installation. 1. One Bin Activator of the vibrating type shall be provided and mounted on a minimum 6-

foot diameter opening of the storage bin. The bin activator shall eliminate bridging, jamming, segregation, rat-holing, and shall ensure a positive continuous flow of chemicals on a first-in, first-out basis. The bin activator shall have a minimum 8 inch diameter plain opening at the discharge with an 8-inch diameter Orbinox knife gate with chainwheel operator accessible from the ground.

2. The Bin Activator shall have a gyrated type hopper with eccentric weights mounted so that vibration is applied perpendicular to the channel flow.

3. The vibrating bottom shall be hung from the bin with rubber-bushed steel hangers and connected to the bins with reinforced butyl sleeve so that no vibrations are transmitted to the bin.

4. Vibration shall be generated by a 3 HP, 460-volt, 3-phase motor-driven eccentric type oil lubricated gyrator. Motor enclosures shall be TEFC. The bin activator shall run continuously during the feed cycle. The discharge spout shall be fitted with a flex connection suitable for connection to the screw feeder. The activator shall be provided with manufacturer's standard shop finish paint. Refer to Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below” for additional requirements.

5. The Bin Activator and gaskets shall be shipped loose to be installed by the CONTRACTOR.

D. The storage silo fill pipe shall be a 4-inch, Schedule 40 steel with 90 degree, 4-foot radius long sweep elbows. The storage fill pipe shall be at the target box on top of the bin. The

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storage bin fill pipe shall be located no further than 4 feet from the unloading control panel. The fill line shall be provided with a dust cap and limit switch.

2.3 LIME FEED SCREW CONVEYOR

A. The Conveyors shall be designed to convey quicklime in accordance with section 2.1 and in accordance with the layout shown on the contract drawings. The screw shall operate at an approximate speed of 2-20 RPM.

B. The Screw shall be of the standard sectional flight type. The flights shall be at least 1/4-inch thick, fabricated from carbon steel. The flights shall be a minimum of 6 inches in diameter.

C. The troughs shall be of the formed flange type. The troughs shall be fabricated from 1/4 inch thick carbon steel. The formed flanged trough covers shall be minimum 14-gauge carbon steel.

D. The screw flights shall be mounted on the proper size and type pipe so that deflections shall not exceed 1/4 inch between standard hanger bearing intervals. Provide split hard iron inserts tapped for grease lubrication. The CONTRACTOR shall provide extended grease piping from the trough covers to convenient access points located on the conveyor supports.

E. Tail bearings shall be of the flanged external ball bearing type with grease fitting. The trough shall be sealed with a lip type plate seal to minimize lime dust. Flexible connections shall be used for all transfer chutes.

F. The Lime Feed Screw Conveyor shall include a motor, which shall be directly connected to the speed reducer. The speed reducer shall be directly connected to the feeder screw. The drive shall SEW Euro drive’s standard F series. The motor horsepower shall be 2 HP.

G. The motors shall be connected to the speed reducers through belt drives which are suitably covered with a 14 gauge OSHA-approved guard. The motor shall be 480 volt, 3 phase. The speed reducer shall be the screw conveyor/shaft mount type meeting CEMA specifications.

H. The conveyor shall be supported by steelwork of angle construction, cross braced sufficiently to support all anticipated loading. The existing Volumetric Feeder base at the Silo platform shall be reused to support the tail end of the Lime Feed Screw Conveyor.

I. A 1/2 HP, 480 volt, fan shall be provided atop the discharge of the conveyor to place positive pressure through the process train, minimum 1200 cfm at 6-inch WC.

J. All steelwork is to be sandblasted to SSPC-SP10, followed by two coats of Tnemec 66-1211 Epoxy Primer at 3.5 mils DFT.

K. The hose connection from lime transfer screw conveyors to sludge/lime mixers shall be thermo-plastic rubber hose designed for temperatures ranging from -50oF to 275oF while maintaining flexibility.

2.4 SLUDGE/LIME MIXER

A. The Contractor shall furnish one (1) Sludge Lime Mixer. The Sludge/Lime Mixer shall consist of twin mixing flight assemblies, with one (1) common drive unit. The housing shall consist of a 1/4” thick carbon steel superstructure which shall house the augers, 304 SST trough, heat system and covers. The 304 SST trough shall be bolted to the housing and be provided with a 6” drain for use in daily maintenance. The end plates shall be minimum ½-inch thick. Provide 304 stainless steel supports. Supports shall be adequately sized to support equipment per the drawings.

B. The Sludge/Lime Mixer shall be provided with an insulated trough. The trough shall be insulated with a minimum two (2) inches of insulation material. Insulation shall be designed to withstand a maximum temperature of 2,200°F. The insulation shall be provided with a minimum "K" value of 0.6. The insulation shall be sealed from moisture of steam generated by the sludge.

C. The tail shaft bearings shall be flange roller bearing design. The bearing housing shall be painted with the manufacturer's standard factory finish. The trough shall be sealed with a plate-type seal or packing gland seal to prevent sludge from passing through the seal and

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into the bearing. All bearings shall have a B-10 life of 100,000 hours as defined by AFBMA Standards.

D. Provide a minimum 10-HP, 460-volt, 3-phase motor and speed reducer. The speed reducer shall have a service factor of 1.4 as defined by AGMA Class II Standards and shall be based on the calculated developed horsepower. The motor shall be controlled by an adjustable frequency speed drive furnished by the manufacturer and located inside the Lime System Control Panel. Refer to Section 16150, “NEMA Frame Induction Motors, 600 Volts and Below” for additional requirements.

E. The Sludge/Lime Mixer shall have two (2) mixing flight assemblies, minimum 14-inch each, all 304 SS mounted on a 304 SS steel pipe or solid bar stock. The flight assemblies shall span the trough ends with no more than 1/4-inch deflection without intermediate hanger bearings. The trough covers shall be 10 gauge, 304 stainless steel. The cover shall be bolted and gasketed in place. Cover bolts shall be 304 EZPL. Provide one (1) 18-inch square inspection hatch with a handle. The opening shall have a safety grid.

F. The Sludge/Lime Mixer shall be equipped with an electrical resistance heating system to keep the trough from freezing. The Heat System shall consist of two (2) external heat zones which shall provide 24 kilowatts of power. The Heat System shall include all temperature sensing probes necessary to properly control the Heat System and to protect the System from excessive temperature. Additional temperature sensors shall be provided as spares as shown on the electrical drawings.

G. All steelwork is to be sandblasted to SSPC-SP10, followed by two coats of Tnemec 66-1211 Epoxy Primer at 3 to 5 mils DFT.

2.5 BELT CONVEYOR

A. The belt conveyor shall be designed to convey 12 wet tons stabilized sludge with a bulk density ranging from 40 to 60 pounds per cubic foot.

B. The conveyor shall include a motor, which shall be directly connected to the speed reducer. The speed reducer shall be directly connected to the head pulley shaft. The drive shall be SEW Euro drive’s standard F series. The motor horsepower shall be 5 HP, 480 V, 3 ph., 60 Hz and comply with Specifications Section 16150.

C. Pulleys & Bearings: The pulleys are to be 12-inch diameter minimum with tapered "QD" compression type hubs mounted on cold rolled steel shafting supported by 1 15/16-inch diameter minimum self-aligning roller bearings. The head pulley shall have 1/4-inch thick vulcanized neoprene lagging to prevent a belt slip. The tail pulley shall be supported by protected screw take-ups with 12-inch take-up length minimum. The take-ups shall include stainless steel adjusting rods with brass bearing capture nuts.

D. Belting & Splice: 1. Belt conveyor shall incorporate a 2-ply nylon carcass belt, 24-inch wide with 1/8-inch x

1/16-inch oil resistant nitrile covers and rated tension of 220 P.I.W. 2. The belt will be spliced by hot vulcanizing to be done in the field by the CONTRACTOR

per manufacturer’s instructions.

E. Idlers: 1. Belt shall be supported on the carrying run by CEMA Type B, 20 degrees troughed

idlers on 4'-0" centers except at the load points on 2'-0" centers, and return runs on CEMA idlers at maximum spacing of 10'-0". Flat idler shall be provided at the horizontal run where the plows are located.

2. Idlers are to be covered with corrosion and wear resistant 1/8-inch thick molded urethane and supported from the frame by hot dipped galvanized brackets.

3. Idlers shall include 3/4-inch diameter shafts and tapered roller bearings with one side regreaseable. Shaft seals shall be multi-passage labyrinth with a positive wiper and an outer shield constructed as recommended by CEMA.

F. Frame: 1. Belt conveyor frames and supports shall be constructed of ASTM A36 structural

members with spreaders, sized as required to limit deflection to 1/250 at the longest support span. Top of channel frames shall be covered with 18 gage, 304 stainless

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steel return belt cover to prevent product spillage onto the return run of the belt. Frame and support assemblies are to be hot dipped galvanized ASTM A123 after fabrication.

G. Accessories: 1. Skirting: Conveyor shall be provided with continuous 18 gage, 304 stainless steel skirt

at load area with an adjustable neoprene seal strip at the belt to guide and control the product. Frame design may be either truss or channel type.

2. Drip Pan: Return run of the belt shall be provided with an 18 gage drip pan 6 inches wider than overall belt width with water tight flanged connections in 10'-0" maximum lengths. Drains shall be located as shown on the drawings. The drip pan shall be installed to serve as a guard for the return run of belting.

3. Guards: Conveyor shall be provided with OSHA style guards at all "nip points" and motor driven rotating components, specifically including motor drive and tail pulley and head pulley guards. Guards shall be constructed of 304 stainless steel.

4. Switches: The conveyor shall be provided with a cable operated OSHA safety stop switch with continuous cable run on both sides and a zero speed switch mounted at the conveyor tail shaft. Switches shall be SPDT, 120 vac.

5. Belt Wiper: The product shall be scraped from the belt surface by a spring tensioned adjustable neoprene scraper blade. The blade will be tensioned by (2) adjustable 304 stainless steel springs.

H. Belt Plows: 1. Belt conveyor shall be able to discharge at two (2) intermediate points along the belt via

electrically operated, one-side discharge belt diversion plow assembly. 2. Diversion plow shall operate by means of an electro-mechanical liner actuator, sized as

required, to operate the diversion plow at a speed of not less than two inches per second. Actuator shall be as manufactured by Limitorque, Rotork, or EIM.

3. Diversion plow blade shall include ½” thick, replaceable, adjustable, rubber seal strip with steel baker plate.

4. Mechanical stops shall be provided to prevent diversion plow blade from contacting the belt.

5. Mechanical stops shall be provided to prevent diversion plow blade from contacting the belt.

6. Diversion plow frame shall be fabricated from suitable structural shapes to support diversion plow blade and actuator.

7. Belt diversion plow assembly shall operate over a flatbed plow deck of ¼” thick plate having replicable 3/8” thick UHMW-PE cover plate and supporting steel as required to support plow deck and plow discharge chute. a. Steel components shall be fabricated from T-304 stainless steel b. Plow deck shall include lead-on and lead-off rollers to prevent belt misalignment

8. Tapered skirting shall be provided upstream of the diversion plow assembly to prevent material from falling off the belt of stockpiling along the edge of the plow deck.

9. Inlet and discharge chute: Transfer chutes shall be provided at all points where belt conveyor is loaded or discharged. The chutes shall be fabricated from a minimum 10 gauge plate steel, adequately stiffened. The design of the chutes shall take into consideration material trajectory and minimization of material buildup. Transfer shall be designed to direct material to the center of downstream device. Openings with tight covers shall be provided in the chute as needed for servicing of belt cleaners and other equipment, adjustments of deflectors and observations of material trajectory.

10. Spare Parts: The Conveyor shall be provided with the following spare parts. a. (1) Bearing of each size b. (2) Carry Idlers c. (2) Return Idlers d. (1) 10’ Belt Length e. (1) Belt Splice Kit with Tools f. (3) Belt Wiper Blades

11. OSHA approved weather-tight covers shall be provided for the portion of the conveyor that extends from the sludge/lime mixer discharge to the transition to a horizontal conveyor underneath the solids loadout area roof. They shall be of the full hood type with locking eyebolts and quick opening wing nuts. The hoods shall be minimum 22 gauge galvanized steel.

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12. Coating: Fabricated mild steel frames and supports shall be hot-dipped galvanized, ASTM-A123 after fabrication. Component hardware shall be epoxy painted. Non-ferrous items shall remain unfinished. Shafting shall be coated with a rust inhibitive compound equal to Mobil ARMA 633.

13. Fasteners: Component assembly shall be achieved with 304 stainless steel, bolts, flat and lock washers prepared with anti-seize compound prior to engagement.

2.6 CONTROLS

A. Control Panel Construction Requirements: Refer to Section 16486 Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs), for the construction requirements of each Control Panel. All panels specified under this Section, shall be submitted as a part of each associated mechanical equipment submittal.

B. Lime Truck Unloading Panel (LTUP) 1. An integrated control system shall be furnished to completely control the operation of

the lime truck unloading system, including the Dust Collector and the three (3) bin level detectors. The panel shall be built by a U.L. approved facility.

2. System Component Identification: a. On-Off: Control Power selector switch b. On Light: Control Panel c. Hand-Off-Auto: Dust Collector Fan d. Hand-Off-Auto: Dust Collector Shaker e. Run Light: Dust Collector Fan f. Run Light: Dust Collector Shaker g. (3) Indicating Lights: Silo level high, reorder, low h. Alarm Horn: Silo level high i. Push-Button: Alarm horn silence

3. The lime filling station is utilized to facilitate the loading of lime into the silo. An independent contractor shall deliver lime from a bulk truck that utilizes its own pneumatic delivering system. The truck shall connect to the “EVER-TIGHT” cast iron adapter on the fill pipe. The removal of the cap causes actuation of the limit switch which initiates operation of the dust collector. The dust collector shall continue to run while the driver delivers his entire load of lime. After delivering his entire load of lime, the truck driver shall remove and replace the fill pipe cap which immediately shuts down the dust collector fan. After the dust has settled for (30) seconds, the shaker shall run for thirty (30) seconds to clean the filter bags.

4. The LTUP shall contain lights for run status, control power, and (3) silo levels. If the silo level reaches “High,” then the alarm horn shall sound alerting the driver to end his delivery. The horn may be silenced, and the high level light shall reset after lime has dropped below the “high level” switch.

5. The power source (by others) to the Lime Truck Unloading Panel shall be 480 VAC, 30 amps, 3-phase, 60 Hz. The LTUP shall be a NEMA 4X stainless steel enclosure with integral safety disconnect switch, and shall contain the motor starters for the dust collector. The LTUP shall be wall mountable, and shall interface the Stabilization System Control Panel as necessary.

C. Stabilization System Control Panel (SSCP) 1. The control panel shall be furnished by the Lime Stabilization System supplier. The

panel shall be built by a U.L. approved facility. The panel shall be inspected, approved and labeled, prior to shipment, in accordance with U.L. 508 requirements. The control panel shall be a NEMA 4X 316 stainless steel enclosure. The control panel shall be complete with all instrumentation, wiring, and other devices as required, and delivered to the site as one prewired coordinated unit ready for field wiring. A 480 VAC, 80 Amp, 3 phase, 60 Hz power supply circuit shall be provided to the panel by others. The control panel shall have an external pad-lockable operating handle to disconnect all power to the control panel by opening a thermal-magnetic circuit breaker. A control power transformer shall be provided, with a control power selector switch and indicating light. FOPP-SSCP shall also be provided by the PCSI and installed within the new stabilization System Control Panel to land the FOC-SSCP fiber strands. The SSCP control panel shall be mounted on 12-inch stands.

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2. All control panels shall comply with the requirements of specification section 16486 Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs).

3. The SSCP shall be a PLC-based control panel to control and monitor the Sludge Stabilization Process in both automatic and manual modes. The PLC shall be an Allen Bradley ControlLogix or CompactLogix series. The SSCP shall be furnished with a System “Manual-Auto” selector switch. In the “Auto” mode, the PLC shall control start, stop, and fault shutdown sequences with interlocking such that no equipment can discharge onto a non-moving conveyor. In the “Manual” mode, the PLC shall allow independent equipment control without interlocks (except E-Stop). All motor starters and adjustable speed drives shall be furnished by the Lime Stabilization System supplier in the SSCP. The SSCP shall interface the LTUP as required. The SSCP shall provide the following functions: a. System “Auto-Manual” control, b. Off-Auto-On control of each motor, c. Speed potentiometers for each adjustable speed drive, d. Control of the Sludge/Lime Mixer heat system, and e. Each conveyor shall be able to be individually operated.

4. The Belt Press Control Panel shall be modified by others to furnish the SSCP a signal indicating that sludge is present. The SSCP shall initiate shutdown procedure upon loss of signal.

5. The belt conveyor and sludge/lime mixer shall each be furnished with (2) two safety pull cord switches. If any safety pull cord switch is activated, then all pieces of equipment shall immediately shut down and an alarm signal shall be sent. The belt conveyors, sludge/lime mixer, and the lime feed screw shall be furnished with zero speed switches.

6. The SSCP shall interface with the plant SCADA system via Ethernet communications for monitoring purposes only. a. Run status of all equipment including existing Lime Storage Silo equipment b. Failure status of all equipment including existing Lime Storage Silo equipment c. Operating Mode of SSCP System d. Lime Storage Silo High Level e. Lime Storage Silo Reorder Level f. Lime Storage Silo Low Level g. Provide the capability for the SCADA Control System to monitor an additional 15

digital signals. These digital signals will be further defined during the Application Services Provider (ASP) graphics workshops. Reference specification section 13305.

h. Provide the capability for the SCADA Control System to monitor an additional 5 analog signals. These analog signals will be further defined during the ASP graphics workshops. Reference specification section 13305.

7. The SSCP shall interface with both of the Belt Filter Press Control systems via hardwired signals as shown on the contract drawings: a. SSCP System E-Stop #1 b. SSCP System E-Stop #2 c. SSCP System E-Stop #3 d. SSCP System Running e. SSCP System Fault f. SSCP System Ready g. Belt Press Run Request (From Belt Filter Press Control Panel).

8. A Heat System Power Control Center (HSPCC) shall be provided, to power the system’s Sludge/Lime Mixer’s heat circuits and provide proper interlocking and over-temperature protection. The HSPCC shall be a 316 Stainless Steel NEMA 4X enclosure installed by the CONTRACTOR. This enclosure shall be mounted on 12-inch stands. The Control Center shall be manufactured and assembled in a UL registered shop. All components (relays, breakers, pilot devices, etc.) wiring and labeling shall be the System Supplier’s standard to meet UL requirements. Prior to shipment, all control panels shall be inspected, approved and labeled in accordance with UL 508A Requirements. The control panel shall be furnished by the manufacturer.

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2.7 ACCEPTABLE MANUFACTURERS

A. The acceptable equipment for the lime stabilization system rehabilitation shall be manufactured by RDP Technologies, Inc. of Conshohocken, Pennsylvania. The representative for RDP Technologies, Inc. for this area is Environmental Improvements, Inc., 517 North Kealy Drive, Lewisville, Texas 75057, Telephone No. (972)436-2536.

B. The OWNER has received a not-to-exceed quote for the equipment described herein from the representative in the amount of $688,750.00. The quote is attached to the end of the specification and includes the scope of the work to be performed by the manufacturer. In case of any conflicts between the OWNER’s conditions and the Equipment Manufacturers terms and conditions, the OWNER’s conditions shall supersede the Equipment Manufacturer’s.

PART 3 - EXECUTION

3.1 INSTALLATION

A. All sections and loose items shall be match-marked prior to shipping.

B. Installation shall be in accordance with the manufacturer's installation requirements.

C. Upon successful start-up and training of the system, the CONTRACTOR shall work with the plant operating personnel to furnish and install extended grease lines. Their location should be convenient to the operation standard maintenance procedures.

3.2 FIELD TESTS

A. The equipment shall be field tested after installation to demonstrate satisfactory operation without causing excessive noise, vibration, and overheating. The field testing shall be performed by an experienced field representative of the manufacturer of each major item of equipment, who shall supervise the following tasks and shall certify in writing that the equipment and controls have been properly installed, aligned, lubricated, adjusted, and readied for operation: 1. Start up, check, and operate the equipment over the entire speed range to verify

capacity. 2. Upon satisfactory completion of the installation, start-up, and instruction phase, an

installed performance test shall be performed by the manufacturer. 3. The performance test shall be conducted to demonstrate to the OWNER/ENGINEER

that the installed sludge/lime blending system can conform with the performance requirements in these specifications.

4. Prior to performing the performance test, the ENGINEER shall conduct a pretest meeting with all involved parties to discuss method of analyzing samples, etc.

5. The OWNER shall provide all sludge feed, water, polymer, electrical power, and dewatered sludge disposal, etc., necessary to conduct the installed performance tests.

6. The equipment manufacturer, with the assistance of the OWNER’s personnel, shall place all system components necessary for the operation of the sludge/lime blending system into successful operation. The belt press and associated equipment shall be started up prior to sludge testing of the lime stabilization system.

7. The performance test shall occur on a weekday between the hours of 8:00 a.m. and 5:00 p.m. The manufacturer shall be allowed to operate and determine the optimum operating conditions prior to the time of the test.

8. The following performance testing shall be conducted to verify pH and indicator organism levels. a. Performance tests shall be conducted for two consecutive days. Three random

samples shall be taken each day. All sampling and sample handling shall be done in accordance with the U.S. EPA POTW Sludge Sampling and Analysis Guidance Book.

b. Samples shall be tested in accordance with Standard Methods 908 and 910A for fecal indicator organisms and EPA Procedure No. 9045 pH. All sampling shall be done by an independent analytical laboratory.

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c. The pH must be 11.5 or greater after 24 hours. The samples shall contain less than 1 million living organisms, for fecal coliform and for fecal streptococci, per gram of dry solids.

d. The mixer shall produce a granular end product with an angle of repose, after mixing, equal to or greater than the angle of repose of the sludge fed to the mixer. The mixer shall meet this requirement at the minimum lime dosage required to obtain the pH specified. The use of additional lime to meet the angle of repose test is not acceptable. The manufacturer shall modify the design of the mixer, at no additional cost to the OWNER, in order to comply with these requirements. The equipment shall be deemed to have successfully passed the performance test if the average results of all samples are in conformance with the specified performance requirements.

e. The OWNER, at his option, may require the manufacturer to remove the installed equipment and contract with another manufacturer to provide equipment that will meet all requirements of the specification, or require the manufacturer to pay a penalty to the OWNER. The penalty amount shall equal the extra cost that will be incurred by the OWNER.

9. The OWNER will have an independent laboratory perform the testing. The OWNER will pay for the first set of tests unless the tests fail. The Manufacturer shall pay for the failed tests and any and all additional tests required to demonstrate performance.

10. The equipment manufacturer, with the assistance of the ASP, shall confirm and make operational communication with the existing Control System over the specified Ethernet communications network.

11. The equipment manufacturer, with assistance of the ASP, shall coordinate, verify and make operational all monitored I/O at the SCADA Control System.

12. The equipment manufacturer, with the assistance of the ASP and Belt Press Equipment vendor, shall coordinate, verify and make operational the monitoring/control of all hardwired I/O, as necessary, for the overall operation and functionality of the Lime Stabilization System and the Belt Press Systems.


A. The equipment manufacturer’s representative shall: 1. Approve installation before operation. 2. Perform acceptance test and operate system to verify satisfactory operation of each

unit in presence of ENGINEER and OWNER’s personnel, and provide certified field test reports as required by Section 01300. Check units for excessive noise, vibration, alignment, general operation, etc.

3. Verify conformance to requirements. 4. Instruct plant personnel on care and maintenance. 5. Revisit jobsite as often as necessary to correct deficiencies to satisfaction of

ENGINEER.

END OF SECTION

960 Brook Road Phone: 610-650-9900

Building Eight Fax: 610-650-9070

Conshohocken, PA 19428 E-mail: [email protected]

www.rdptech.com

TO: Jeffery Caffey Date: July 6, 2016

Alan Plummer Associates, Inc.

RE: Flowermound, TX

Wastewater Treatment Plant

Rehabilitation Phase IV

Solids Facility Improvements Part 1

Mr. Caffey:

RDP Technologies, Inc. will be offering pricing for the following equipment based upon our

interpretation of the specifications provided July 6, 2016 and further clarified by this letter, as well as the

attached General Terms and Conditions.

Section 11151 Lime Stabilization System Rehabilitation

Part 1 General

1.1 Related Documents: Included.

1.2 Summary: Included. Exclusions listed further.

1.3 Quality Assurance: Included.

1.4 References: Included.

1.5 Submittals: Included.

1.6 Experience Requirements: Included.

1.7 Delivery, Storage and Handling: Delivery Included. Storage and Handling is Not Included.

1.8 Special Equipment Warranty: Included.

Part 2 Products

2.1 Design Criteria: Included.

2.2 Lime Storage Silo Replacement Components: Included. Removal of Existing Components and

Installation of New is Not Included.

2.3 Lime Feed Screw Conveyor: Included.

2.4 Sludge/Lime Mixer: Included.

2.5 Belt Conveyor: Included.

2.6 Controls: Included.

2.7 Acceptable Manufacturers: Included.

Part 3 Execution

3.1 Installation: Not Included.

3.2 Field Tests: Included.

3.3 Field Quality Control: Included.

mailto:[email protected]

All General Contractors

Page 2




www.rdptech.com

Exclusions Include, But Are Not Limited To:

Anchor bolts

Installation

Disconnect switches

Unloading of equipment

Wiring, conduit and connections including field wiring terminations at RDP panels

Arc Flash Analysis, PPE requirements and labeling of RDP Panels

Updated Plant SCADA integration

Hand Stations for Dumpster Veyor control

Removal and replacement of Lime Silo replacement components

Lime fill line piping supports

Lightning Protection

Foundations and foundation design

Modifications to existing Belt Press Conveyor and it’s discharge Chute

Field modifications of existing Volumetric Feeder support stand

Platforms shown on drawings S-806 and S-807

Initial chemicals and lime

Initial lubricants

Extended grease lines

Water supply and piping

Drain piping

Equipment Tags

Supports for Odor Control Hoods

Costs for Bonds

Taxes of any type

Intermediate or finish painting

Painting over galvanized or stainless steel equipment

Laboratory testing during performance testing

All pricing is based upon RDP receiving 95% of the contract price upon delivery to the job site. 2 1/2%

due upon mechanical start-up and the final 2 1/2% due upon successful performance testing. Shipments

may be made as soon as 8 weeks after drawing approval. In the event that there is no appropriate on-site

storage, RDP will be paid for materials stored off site. Partial shipments, billings and payments will be

required. Payment for start-up and testing will be due upon completion but no later than 180 days after the

Delivery. Payment to RDP is not contingent upon the actions of third parties.

Our pricing assumes that RDP can ship equipment when ready and receive payment for stored materials.



Page 3




www.rdptech.com

Not to Exceed Price: $688,750.00 F.O.B. factory with freight allowed to job site.

If you have any questions, need additional information; please do not hesitate to contact our local

representative.

Mr. Fred Wilms

Environmental Improvements, Inc.

Phone: 972-436-2536

Very truly yours,

Richard W. Christy, President

RDP Technologies, Inc.

DC:mq

Attachment: Terms and Conditions

F:\Preproject\Flowermound, TX Upgrade\RDP Flowermound, TX Upgrade Scope 20160609



Page 4

TERMS AND CONDITIONS This scope letter and any resulting purchase order shall be subject to the following terms and conditions except as otherwise agreed to by an officer of the company or in RDP's letter acknowledgment acceptance of your purchase order. Commencement of the work shall not constitute acceptance by RDP of additional or different terms and conditions. This scope letter has been prepared to provide a service for use in preparing your bids. The nature of the business is such that it is impossible to cover all of the technical and commercial details of a proposal in the brevity that is required for a construction company to prepare a bid for this industry. The information contained in our scope letter represents our interpretation of the consulting engineer's plans, specifications and intentions. We cannot be responsible for the interpretation of these documents and the definition of these responsibilities. We trust that the information contained in our scope letter will be of some assistance and guidance to you in the preparation of your bid for the subject project. The pricing is based on many factors and should be considered valid for 30 days. After 30 days, the pricing may need to be revised to reflect changes in RDP's costs and availability of our production capabilities. 1. Delivery

a. Unless otherwise specified, delivery shall be made F.O.B. point(s) of shipment with freight allowed to designated jobsite based on said jobsite being accessible by common carrier.

b. Shipment will be made approximately 8 to 22 weeks after receipt of final drawing approval, consummation of all

technical/commercial details and/or release for fabrication. c. RDP shall not, in any event, by contract or otherwise, be liable for delays in performance caused by any factor beyond RDP's

control such as, but not limited to; (1) acts of governmental authorities, (2) acts of God, (3) casualty, (4) civil disturbance, (5) insurrection, (6) labor strikes or disputes, (7) inability to obtain materials, (8) delay in consulting engineer's approval of submittal data and drawings, and/or (9) delays by transportation carriers.

d. Buyer must accept shipment when RDP advises equipment is ready for shipment. If buyer cannot accept shipment, then

buyer agrees to submit invoices for progress payments for materials stored offsite at locations determined by the seller. Seller agrees to furnish photographs of completed equipment and copies of property insurance to the buyer.

e. In the event the contract shipping date is extended by acts of buyer including, but not limited to, unreasonable delays in

approval of submittal drawings, escalation of the selling price at the rate of 1.5% per month for each month or partial month of delay, shall be applied.

2. Prices

Prices specified herein do not include any sales use, excise, occupational or similar taxes and/or license fees in connection with the engineering, manufacturing, sale or delivery of the equipment. Such taxes and fees shall be paid by the buyer directly to the taxing and/or licensing authorities or the buyer shall submit to RDP a proper tax exemption certificate acceptable to such authorities.

3. Terms of Payment Unless otherwise specified in this scope letter, terms of payment shall be 100% of invoice, net thirty (30) days from the date of

shipment. Overdue invoices will be subject to 1.5% per month finance charges. 4. Field Service

(Start-Up and Instructions) a. If jobsite field service is included in RDP's prices, it will be so stated in this quotation and the number of days and trips included

will be so specified. In the event the Buyer requires such services for additional days or trips, RDP shall invoice the Buyer at a rate of $1,285.00 for each additional day plus travel and lodging expenses incurred by the service personnel during such additional days.

b. The per diem rate is subject to change to the rate in effect at the time such service is furnished. c. The Buyer is to indemnify and hold RDP Technologies, Inc. harmless from and against all suits, legal expenses, claims,

judgments for personal injury to or death of our or your employee(s) or third parties or from damage to property resulting from any act of our employee(s) or agents while at the jobsite except if such injury, death or property damage is directly caused by the sole negligence of RDP's employee(s) or agent, but in no event shall RDP be liable for indirect or consequential damages.

d. RDP requires a minimum of four (4) weeks notice prior to start-up in order to effectively schedule our work force.


Page 5

5. Safety The equipment covered in this proposal shall be designed in accordance with RDP's engineering standards and interpretation of the

requirements of the Occupational Safety and Health Act of 1970. 6. Shortages

(Manufacturing Discrepancies) a. Notify the RDP Technologies, Inc. immediately upon discovery of any apparent manufacturing discrepancies or material

shortages. b. Fabricated steel parts and assemblies furnished by RDP are manufactured in accordance with acceptable shop practices and

standards of the industry. However, some misfits and imperfect work may arise. In such cases, the American Institute of Steel Construction "Code of Standard Practice, Section 5-150" is to be understood to apply to erection of this equipment. It reads as follows: "Correction of minor misfits and a reasonable amount of cutting and reaming are considered a part of erection. Any error in shop work which prevents the proper assembling and fitting of parts by the moderate use of drift pins or a moderate amount of reaming, chipping or cutting, should be immediately reported to the fabricator so that he may either correct the error or approve the method of correction that is to be used."

7. Backcharge Policy No backcharges will be allowed without prior approval from RDP. Written authority must be given in the form of a purchase order.

Authority will be issued when the extent of such modifications and the price for performing these modifications have been agreed upon between the contracting parties.

8. Title: Lien Rights The equipment shall remain personal property of RDP regardless of how affixed to any realty or structure until the price (including any

notes given therefore) of the equipment has been fully paid in cash. RDP shall, in the event of the Buyer's default, have the right to repossess such equipment.

9. Order Cancellation The Buyer may cancel this order at any time but only on terms which will save RDP Technologies, Inc. harmless from all loss. 10. Limitation of Liability

a. RDP shall not be liable under any Contract, or otherwise, for consequential or economic damages such as, but not limited to: (1) loss of use of property, (2) damage to property, (3) increased costs of operations, (4) loss of capacity, (5) loss of profits, (6) fines, (7) penalties, and/or (8) liquidated damages arising in connection with the delivery, sale or use of or inability to use the equipment covered by this order.

b. RDP's liability under any Contract or otherwise, shall not (in the aggregate) exceed the Contract value.

11. Changes Additional engineering work may be required based upon reasonable errors and omissions by third parties. RDP has estimated the cost and bid for this project with the assumption that the plans and specifications are complete and current. Any additional drafting time will be billed at a rate of $285/hr., engineering time will be billed at $425/hr., and project management time at $585/hr.

This scope letter may be changed or revoked and withdrawn by the RDP Technologies, Inc. at any time upon written notice to the

Buyer. 12. Disputes Any controversy or claim arising out of or relating to this contract, or breach thereof, shall be settled by arbitration administered by the

American Arbitration Association under its Construction Industry Arbitration Rules, and judgment on the award rendered by the arbitrator(s) may be entered in any court having jurisdiction thereof. The arbitration shall be held in Montgomery County, Pennsylvania.

13. Exclusive Warranty RDP’s Warranty is for workmanship and materials. RDP will provide parts only. Labor is specifically excluded. Furthermore, RDP

does not warrant that its’ goods or services will accomplish any particular result. All other warranties, expressed or implied, are

excluded from the contract. 14. License Agreement

A. RDP Technologies, Inc. hereinafter designated as the "COMPANY", has obtained, and is the sole owner of U.S. Patents and other Patents Pending relating to apparatus, processes (including the process steps), and manufacturing techniques for waste


Page 6

sludge treatment and/or Pasteurization and Lime Slaking, and has filed related divisional and continuation patent applications covering the apparatus and process (all hereinafter referred to as the "Patent Rights").

B. The COMPANY hereby grants to the City or Operating Body, hereinafter referred to as the "OWNER", a non-assignable,

nontransferable, non-exclusive, paid-up license to use (but not any right to make or sell), in the geographic area represented by the boundaries of the OWNER, the equipment sold by the COMPANY for use of the OWNER.

C. This License Agreement shall apply to the system and equipment to which the COMPANY has said Patent Rights therein,

include equipment sold by the COMPANY to or for the benefit of the OWNER in connection with the sales agreement governing the sale of equipment of the COMPANY for use by the OWNER.

D. The COMPANY and the OWNER desire to operate the equipment to comply with the environmental control standards set forth

by the U.S. EPA. Any use under this License Agreement of the System to which the Patent Rights pertain is to be commensurated with the capacity for which the equipment is designed. For use of the COMPANY System covered by the Patent Rights at more than one (1) location within the OWNER, an additional license will be required for each additional location.

E. The term of the license will commence upon receipt and acceptance of a Purchase Order by the COMPANY and will be in

effect through Construction and Final completion of the Contract. The License will renew at that time provided full and final payment, minus any agreed upon penalties that are part of the performance requirements, by the OWNER for all equipment sold under this Agreement by the COMPANY for use by the OWNER under Paragraph C hereof and continue through the life of said Patent Rights for no additional monetary consideration beyond said full and final payment. The parties hereto agree that an unlicensed use of the said Patent Rights, including any equipment, apparatus, or processes covered thereunder, without final payment may occur during a start-up period, but no longer than six (6) months. If payment has not been made in this timeframe a penalty of $1,000.00 per day will be assessed for every day in operation without being provided a License.

F. The License to use the Patent Rights thereunder is personal to the OWNER and the OWNER will not transfer, sublease,

assign, or deliver the sludge treatment apparatus or such license relating to the apparatus or process of the COMPANY'S Patent rights to another without the prior written consent of the COMPANY.

T&C

Rev. 09/10/01 F:\MARKETIN\SCOPE\SCOPE.DOC

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POLYMER FEED SYSTEMS F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 11\11244 POLYMER FEED SYSTEMS.DOC

SECTION 11244 POLYMER FEED SYSTEMS

PART 1 – GENERAL



1.2 SUMMARY

A. Furnish, install, startup, and test, two (2) liquid polymer mixing and feed systems, complete and operable, with all appurtenances and controls, in accordance with the manufacturer’s instruction, as shown on the drawings, and as specified herein.

B. Equipment Manufacturer shall be responsible to coordinate the design, testing, and installation of the equipment.

C. Related Sections: 1. Section 11144 “Belt Filter Press” 2. Division 13 Instrumentation 3. Division 16 Electrical

1.3 REFERENCES

A. The following is a list of standards, which might be referenced in this Section: 1. National Electrical Manufacturer’s Association (NEMA): MG-1, Motors and Generators. 2. National Fire Protection Association (NFPA): NFPA 70, National Electrical Code. 3. National Science Foundation (NSF): NSF 61, Drinking Water Components – Health

Effects (Required for chemical feed and storage systems handling chemicals for use in potable water treatment).


A. The polymer feed system shall have the ability to automatically and accurately meter, dilute, blend, and feed 0.1% to 1.0% liquid polymer solution of commercial grade neat polymer with a maximum specific weight of 10 pounds per gallon. Provide two (2) polymer activation, blending, and feed systems (PFP No. 1 and PFP No. 2). The polymer feed system shall have the automatic/manual control and shall be capable of being flow paced.

B. Equipment shall be designed and capable of either continuous or intermittent operation.

C. All equipment, supports, anchors and fasteners shall be of adequate strength to withstand loads associated with starting, turbulence, thrusts from liquid movement, thermal expansion and contraction and other loads encountered under normal operating conditions.

D. The equipment, sizes, materials, and arrangements described in this specification section are based on recommendations by equipment manufacturers and shall be considered minimum limits of acceptability. The equipment manufacturer shall be responsible for design, arrangement, and performance of all equipment supplied under this section. Arrangements other than those shown on plans shall be subject to ENGINEER's approval.

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1.5 SUBMITTALS

A. Submittals shall be prepared and submitted in accordance with Division 1.

B. Equipment Operation described below is for reference only. Equipment manufacturer shall furnish a complete and detailed Control Narrative with all Equipment operational features (Local & Remote modes) with all Permissives and Interlocks.

D. Shop Drawings: The following submittals are required, at a minimum, in addition to any other applicable requirements of Section 01300 “Project Documentation”.

1. Shop drawings specific to project and applicable product data bound neatly in a single package. The following information shall be included as a minimum:

a. Manufacturer and model number of equipment. b. Layout drawings including all proposed system components with dimensions,

clearances required and sized indicated, and total weights of the product as well as coatings for each item furnished.

c. Detailed specifications and data describing the materials of construction. d. Specific design parameters for this project including flow rates. e. Layout, sizes, types and materials for anchor bolts to be furnished. 2. Location of nearest stocking distributor of spare parts. 3. Complete operation and maintenance data for all equipment and controls in

accordance with Section 01300 “Project Documentation”. 4. Startup and test schedule with test procedures in accordance with Section 01600

“Startup, Testing, Commissioning, and Training”. 5. Equipment installation report with field test data and test records in accordance with

Section 01600 “Startup, Testing, Commissioning, and Training”. 6. Warranties and service agreements. 7. Provide a list of installations of the same size and model being proposed.

E. Submittals Quality Assurance/Control 1. All deviations from contract documents shall be clearly identified and approved in

writing by the ENGINEER. 2. Any other information necessary for the ENGINEER to determine compliance with the

specifications. 3. Partial or incomplete submittals will not be reviewed by ENGINEER.


A. Manufacturer's installation report is required prior to final acceptance.

B. All equipment of each type specified in this section shall be supplied by a single manufacturer.

C. Manufacturer shall maintain a complete stock of spare parts commonly needed for the equipment specified at a location within the State of Texas, or shall furnish spare parts within 48 hours of request.

D. Each major equipment item shall have a stainless steel manufacturer's nameplate securely affixed in a conspicuous place on the equipment showing the ratings, serial number, model number, manufacturer and other pertinent nameplate data.

E. Stainless Steel Construction:

1. The equipment manufacturer's shop welds, welding procedures, welders and welding operators shall be qualified and certified in accordance with the requirements of the latest edition of ANSI/AWS D1.1 "Structural Welding Code - Steel" published by the American Welding Society.

2. Fabricate all parts and assemblies from sheets and plates of 304 stainless steel with a 2D finish conforming to AISI 304 and ASTM A666, unless noted otherwise. Fabricate

0523-047-01

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all rolled or extruded shapes to conform to ASTM A276. Fabricate all tubular products and fittings to conform to ASTM A269, A351 and A403.

3. Do all welding in the factory using shielded arc, inert gas, MIG or TIG method. Add filler wire to all welds to provide for a cross section and weld metal equal to or greater than the parent metal. Fully penetrate butt welds to the interior surface and provide gas shielding to interior and exterior of the joint.

4. Field welding of stainless steel will not be permitted except for mounting the supports. 5. Bolts, nuts and washers shall be AISI 316 stainless steel furnished in accordance with

ASTM A193. 6. All fabricated stainless steel components shall be passivated either by electro

polishing process or by a pickling process to ensure the maximum resistance to corrosion. The pickling process shall include complete submersing of stainless steel components in a chemical bath of nitric acid and hydrofluoric acid to remove any resides that may be present on the material as a result of forming, manufacturing or handling. The manufacturer shall submit a letter certifying that the stainless steel components will be passivated by one of the above methods with the submittal.

F. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA

70, by a qualified testing agency, and marked for intended location and application.




A. All equipment herein shall be specifically designed for this service and the environment encountered in this installation. The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other corrosive gases encountered in municipal wastewater treatment plants. Equipment shall be designed and capable of operation at temperature of 45°F to 110°F.

1.9 WARRANTY

A. Special Equipment Warranty. 1. The equipment manufacturers shall jointly warrant to the OWNER and to the

CONTRACTOR that all equipment, including all components of the complete assembly furnished by it hereunder, complies in all respects with the design and specifications of these Documents and contains no defects of material or workmanship.

2. In the event of failure of any part or parts of the equipment during the warranty period due to defects of design, materials, or workmanship; the CONTRACTOR shall replace affected part(s) promptly upon notification by the OWNER. All replacement parts shall be furnished, delivered, and installed at the expense of the equipment manufacturer.

3. The warranty period shall be interpreted as the 24-month period following substantial completion of the specified equipment and shall be exclusive of the time of use of the equipment in installation, testing, adjusting, etc., during the construction period, or of the time in storage, after delivery and prior to installation. Provisional acceptance of the equipment shall not affect the determination of the first year of service. All equipment shall be operated for a minimum 10-day start-up period before final acceptance and before the start of the 24-month warranty period.

4. If the equipment does not meet the requirements of the Specifications, the equipment manufacturer shall correct or service the equipment at no additional cost to meet the specified requirements, where any such deficiencies are the responsibility of the equipment manufacturer. In the event the equipment is unable to meet the specified requirements within the warranty period, the equipment manufacturer shall refund an

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amount equal to the purchase price of new equipment, which will meet the specific requirements. The amount of the refund shall not exceed the purchase price of the equipment to be replaced.



A. All equipment shall be the product of a manufacturer having at least ten (10) U.S. installations in satisfactory service of the type being proposed.

B. A list of similar installations shall be furnished upon request with the shop drawing submittal, including names and telephone numbers of contacts.

1.11 MAINTENANCE

A. Maintenance Service: Supplier shall indicate types, brands, and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment. CONTRACTOR shall provide and install the recommended lubricants.

B. Spare Parts: 1. Spare parts shall include, but not be limited to:

a. Any special tools required for maintenance of polymer blend unit and accessories provided by SUPPLIER.

PART 2 - PRODUCTS

2.1 POLYMER FEED EQUIPMENT

A. General 1. The polymer dilution and feed system shall be capable of effectively activating and fully

blending with water a homogenous polymer solution ranging from 0.1% to 1% concentration.

2. Manufactured by: a. UGSI Chemfeed M - Series b. ProMinent

B. Multi-zone Mixing Chamber: 1. A hydro-mechanical blending device capable of maintaining high energy independent

of plant supplied water pressure shall be provided. 2. The mixing chamber mixing zone shall be clear for viewing purposes. 3. The system shall have a minimum of two mixing zones designed to induce the

required high mixing energy without damaging the polymer’s molecular structure, regardless of flow rate.

4. A variable speed mechanical mixing impeller (if required by the manufacturer’s design) shall be provided designed specifically for effectively inducing high, non-damaging mixing energy. The impeller shall be controlled by an SCR or AFD controller to handle the wide range of polymers available. The mixer drive shaft shall be sealed by a mechanical seal which shall have an integrally mounted and factory plumbed seal flushing valve (if required by the manufacturer’s design).

5. The mixing chamber shall have a maximum rated pressure of 150 psi. 6. Provide a neat polymer check valve specifically designed to isolate neat polymer from

dilution water. The valve shall be designed with an open, unobstructed path to the valve seat. The valve body shall be constructed of Teflon or stainless steel with Viton

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seals. The plug and spring shall be stainless steel. The valve shall be readily accessible for cleaning, shall be easily disassembled and reassembled and shall not require tools for removal, cleaning or replacement. Conventional check valves, ball checks, and/or other check valves that are installed inside the mixing chamber, or which require mixing chamber disassembly for servicing will not be accepted.

C. Dilution Water Assembly 1. A 1” FNPT 304 stainless steel dilution water inlet connection shall be provided for total

flow up to 30 GPM. 2. The dilution water flow rate shall be monitored by a Rotameter type flow meter having a

range of 3-30 GPM. A union shall be provided on the Rotameter to allow easy removal for cleaning.

3. Unit shall have an electric solenoid valve for on/off control of total dilution water flow 4. A differential pressure type low water pressure alarm or reed switches to monitor float

position shall be provided. The switch shall be rated NEMA 4X and manufacture by Ashcroft or equal.

5. Proved a 2-1/2” stainless steel liquid filled pressure gauge to monitor dilution water inlet pressure.

D. Polymer Metering Pump 1. Each unit shall have one (1) neat polymer metering pump integrally mounted on the

system’s skid. The metering pump(s) shall have a range of 0.5 to 5 GPH. Pump shall be positive displacement, progressive cavity type.

2. Provide a calibration column with two full port PVC ball valves having Viton O-rings. The column shall be calibrated for a one-minute drawdown and read in GPH and milliliters.

3. Provide a pressure gauge with a diaphragm isolator to monitor polymer line pressure 4. Provide a thermal type loss of polymer flow sensor. 5. Provide equal pressure relief valve mounted in the pump discharge piping and piped to

the pump suction to protect the system and solution piping.

E. Solution Discharge Assembly 1. A 304 stainless steel solution discharge connection shall be provided for total flow up to

30 GPM, 1” FNPT 2. Provide a 2-1/2” stainless steel liquid filled pressure gauge to monitor system discharge

pressure. Provide a thermal type loss of polymer flow sensor.

F. Controls 1. A control panel integral to the systems frame shall be provided. The enclosure shall be

rated NEMA 4X and constructed of FRP. The control panel shall consist of all digital displays, potentiometers, switches, lights, relays, and other control devices required for a complete operable system.

2. Control Panel Construction Requirements: Refer to Section 16486 Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs), for the construction requirements of each Control Panel. All panels specified under this section shall be submitted as a part of each associated mechanical equipment submittal.

3. Control Devices: a. Fused system ON-OFF REMOTE switch. In remote mode the system shall start

by remote dry contacts. b. “Local/Remote” switch shall be supplied for remote or local pump speed control.

A 4-20 mA input signal shall be supplied by the dewatering equipment panel to pace the polymer pump in remote mode. A potentiometer or VFD keypad shall be supplied for local speed control.

4. Indicator a. System running indicator light b. LCD Display of metering pump output (GPM, GPH) c. Low differential water pressure/flow alarm d. Low polymer flow alarm

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5. Alarms a. Low water differential pressure. Switch rated NEMA 4X. Metering pumps goes to

stand-by mode when low dilution water pressure occurs. The pump automatically restarts when pressure returns.

b. Low polymer flow thermal flow sensor 6. Inputs

a. Remote Start/ Stop dry contact b. 4-20mA metering pump pacing signal

7. Outputs a. System Running (dry contact) b. System in “Remote Mode” (dry contact) c. Alarm – Low Water Differential Pressure (dry contact) d. Alarm – Low polymer flow (dry contact) e. Alarm contacts shall be such that a common alarm output can be provided by

placing jumpers between contacts. f. Analog output pump speed (4-20 mA)

G. Equipment Skid 1. The system’s frame shall be of rugged 304 stainless steel construction. No mild steel

shall be used. All piping shall be rigidly supported. PART 3 - EXECUTION 3.1 INSTALLATION

A. Install all equipment in complete accordance with manufacturer's instructions and recommendations and the requirements of Division 1, and as described herein.

B. Complete equipment installation with controls, safety devices and auxiliary support systems necessary to start the equipment and verify that the equipment functions correctly under no load conditions. Turn rotating equipment by hand to check. Complete cleaning and testing of piping systems. Inspect and clean equipment, devices, piping, and structures of debris and foreign material.

C. Remove temporary bracing supports and other construction debris that may damage equipment.

D. Remove protective coatings and oils used for protection during shipment and installation.

E. Install temporary connections and devices required to fill, operate, checkout and drain the system. Provide temporary valves, gauges, piping, test equipment, and other materials and equipment necessary to conduct testing and startup.

F. Equipment 1. Check equipment for correct direction of rotation and freedom of moving parts. 2. Align equipment to Manufacturer's tolerances. Adjust clearances and torques. 3. Check installation prior to start-up for conformance to Manufacturer's instructions. 4. Adjust or modify equipment to ensure proper operation. 5. Correct any deficiencies or problems noted in Manufacturer's representative's

installation reports.

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A. Manufacturer’s services, including training, shall comply with the requirements of Division 1.

B. The equipment manufacturer shall furnish a qualified field representative for a minimum of two (2) working days to be conducted over at least two trips to the site to inspect all equipment described herein after installation, to assist in troubleshooting, to advise the CONTRACTOR and OWNER during startup and testing, and to instruct OWNER's personnel in routine maintenance and troubleshooting procedures. This period shall consist of a minimum of an 8-hour day and travel to and from the project site shall be the responsibility and at the cost of the equipment supplier.

C. Field representatives shall have a minimum of two (2) years of experience with the operation

of and training on this type of equipment. Factory-employed personnel will be required to perform this service. Sales representatives will only be considered acceptable service technicians if they have three (3) years of experience with the operation of and training on this type of equipment from the manufacturer being supplied and have started up 15 units of a similar size and type from the manufacturer.

D. Two training sessions shall be performed, one in the early morning and one in the late

afternoon. CONTRACTOR shall coordinate the scheduling of such training and start-up assistance with OWNER'S personnel. OWNER may videotape training session. A typed outline shall be handed out at the training sessions and, at a minimum, will include normal operating parameters, alarms, and maintenance.

3.3 START UP AND FINAL ACCEPTANCE

A. Startup of the facility shall be in accordance with Division 1. After initial startup under the supervision of a qualified representative of the manufacturer, a preliminary “running-in” period will be provided for the CONTRACTOR, per the Contract Documents, to make field tests and necessary adjustments.

B. Place each piece of equipment in the system in operation until the entire system is functioning. All components shall continue to operate without alarms or shut downs, except as intended, for ten (10) consecutive days to be considered started up.


D. At the end of the specified period of operation, the equipment system will be accepted if, in the opinion of the ENGINEER, the system has operated satisfactorily without excessive power input, wear, lubrication, or undue attention required for this operation, and if all rotating parts operate without excessive vibration or noise and the desired performance has been obtained.

E. Manufacturer's installation report and complete and Final Operation & Maintenance Manuals

are required prior to final acceptance.

END OF SECTION

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PUMP, VERTICAL TURBINE F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 11\11936 PUMP, VERTICAL TURBINE_REV01.DOC

SECTION 11936 PUMP, VERTICAL TURBINE

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Line-shaft vertical turbine pump(s). 2. Pumping system shall include the following components: pump, motor, and drive

assembly for a complete and operating system. 3. Installation, startup, testing, and placing in service assistance.

1.3 REFERENCES

A. References: Following is a list of standards, which might be referenced in this Section: 1. American Water Works Association (AWWA):

a. E101 Vertical Turbine Pumps-Line Shaft and Submersible Types 2. American National Standards Institute (ANSI):

a. C50.10 – General Requirements for Synchronous Machines. 3. ASTM International (ASTM):

a. A36 – Specification for Carbon Structural Steel b. A48 – Specification for Gray Iron Castings c. A53 – Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded

and Seamless d. A108 – Specification for Steel Bar, Carbon and Alloy, Cold-Finished e. A276 – Specification for Stainless Steel Bars and Shapes f. B505 – Specification for Copper Alloy Continuous Castings g. B584 – Specification for Copper Alloy Sand Castings for General Applications

4. Institute of Electrical and Electronics Engineers, Inc. (IEEE): a. 112 Standard Test Procedure for Polyphase Induction Motors and Generators

5. National Electrical Manufacturer’s Association (NEMA): MG-1, Motors and Generators. 6. National Fire Protection Association (NFPA): NFPA 70, National Electric Code. 7. National Sanitation Foundation (NSF): NSF 61, Drinking Water Components – Health

Effects


A. Design Requirements: 1. Summary: Two (2) vertical turbine pumping units shall be installed in the Plant Water

Pump Station to pump non-potable water throughout the facility. 2. Pumping unit, including controls specified herein, shall be specifically designed for the

following conditions: a. Designed for this service and the environment encountered in this installation,

capable of either continuous or intermittent operation. b. Designed to shut down automatically if any of the following conditions are sensed

by the protective circuitry: c. High motor winding temperature. d. At design flow, pumps shall not start more than three (3) times per hour (with the

pumps alternating). e. Pump and motor shall be capable of being operated by reduced voltage non-

reversing starter or a variable frequency drive.

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3. All equipment, supports, anchors, and fasteners shall be of adequate strength to withstand loads associated with starting, turbulence, thrusts from liquid movement, thermal expansion and contraction and other loads encountered under normal operating conditions.

4. The pump shall be designed to operate for at least 2 minutes against a closed valve without damaging the pump.

5. Refer to P&ID’s, Drawings, and Division 13 Sections regarding the control logic and description for additional pump monitoring and control information as applicable.

B. Service Conditions: Refer to Pump Data Sheet.


A. Guaranteed Performance: 1. Transfer the product at the operating conditions as listed in the Pump Data Sheet. 2. Comply with performance requirements specified, as determined by testing assemblies

representing those indicated for this Project.

B. Guaranteed Efficiencies 1. Pumping unit manufacturer shall provide a statement of the guaranteed pump

efficiency at the specified rated head and capacity with the shop drawings. In determining the bowl efficiency, the complete bowl assemblies shall be tested.

2. Factory testing shall determine the bowl efficiency as the water horsepower developed at the pump bowl discharge divided by the horsepower input to the pump accounting for the motor efficiency.

3. Pump bowl shall be factory tested and certified test results shall be approved by the ENGINEER prior to shipment. If the pump bowl and/or motor does not meet the guaranteed efficiencies after factory testing, or the guaranteed efficiencies are less than the minimum efficiencies specified, the pump may be rejected, or at the OWNER's option, may be accepted for a reduction in the Contract Amount, based on the efficiency evaluation set forth below.

C. Specific Performance Requirements: 1. Refer to attached Pump Data Sheet after End of Section.

1.6 SUBMITTALS

A. Product Data: Provide construction details, material descriptions, dimensions of individual components and profiles, rated capacities, operating characteristics, electrical characteristics, and furnished specialties and accessories.

B. Shop Drawings: Provide plans, elevations, sections, details, and attachments to other work. 1. Detail equipment assemblies and indicate dimensions, weights, loads, required

clearances, method of field assembly, components, and location and size of each field connection.

2. Performance data curves showing head, capacity, horsepower demand, and pump efficiency over the entire operating ranges of the pump, from shutoff to maximum capacity. a. Indicate separately the head, capacity, horsepower demand, overall efficiency,

and minimum submergence required at the guarantee point. b. Reverse rotation characteristics for the pump shall be submitted.

3. Restate note or data sheet. 4. Wiring Diagrams: If applicable, for power, signal, and control wiring diagrams,

including terminals and numbers. 5. Complete motor nameplate data, as defined by NEMA, motor manufacturer, and

include any motor specifications. 6. Documentation demonstrating factory finish is equivalent to finish system specified in

this Section. 7. Equipment weights and lifting points.

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C. Information Submittals: 1. Factory functional and performance test reports and log. 2. Manufacturer’s Certification of Compliance. 3. Special shipping, storage and protection, and handling instructions. 4. Manufacturer’s instructions for installation. 5. Manufacturer’s Certificate of Proper Installation. 6. Qualifications: Manufacturer and manufacturer’s representative. 7. Suggested spare parts list to maintain the equipment in service for a period of one

year. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current pricing information.

8. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for maintenance.

D. Operation and Maintenance Data: For each pumping system to include in operation and maintenance manuals. Provide in accordance with Section 01300 “Project Documentation.”


A. Manufacturer Qualifications: 1. All equipment shall be the product of a manufacturer having at least ten (10) U.S.

installations of the type being proposed, each with a minimum of 5 years of satisfactory service.


3. Certified to ISO 9001 or equal.

B. Installer Qualifications: Manufacturer's authorized representative who is trained and approved for installation of units required for this Project.

C. Source Limitations: Equipment units of each type specified in this section shall be supplied by a single manufacturer. All components for the pumps shall be supplied, assembled, and warranted by one of the approved pump manufacturers. Pump components shall NOT be acquired from separate entities and assembled as a final product by a manufacturer’s representative. Pump manufacturer shall submit a statement that the pumping unit was completely assembled and tested at the manufacturer’s factory.

D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

E. Pre-installation Conference: Conduct conference at Project site.


A. Deliver, handle, and store pumping system components in accordance with manufacturer’s written instructions and the requirements of Section 01400 “Contractor Requirements”.

1.9 WARRANTY


B. The warranty period shall be interpreted as the period following the final acceptance of the installed equipment by the OWNER, and shall be exclusive of the time of use of the equipment installation, testing, adjusting, etc., during the construction period, of beneficial use by the OWNER or of the time in storage, after delivery and prior to installation. Final

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acceptance will not be issued by the OWNER until after successful completion of the performance acceptance test. Before the OWNER can issue the final acceptance, the manufacturer must submit the installation report that includes the methods, results, and conclusions from the performance acceptance test. Equipment shall be operated for a minimum of 30-days after equipment startup before final acceptance. 1. Warranty Period: Two years following final acceptance by OWNER or 30 months from

shipment, whichever comes first.

1.10 EXTRA MATERIALS

A. Furnish extra materials that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.

B. Provide one (1) set of spare parts for all components exposed to operational wear during normal equipment service. Spare parts shall include, but not be limited to: 1. One replacement mechanical seal 2. Special tools necessary to maintain the equipment. 3. Other parts recommended by the manufacturer as typically needed in the first two

years of operation.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Fairbanks Morse 2. Flowserve 3. Xylem Goulds Water Technology

2.2 PUMP CONSTRUCTION

A. General Requirements: 1. Pumping unit shall be designed and manufactured in accordance with AWWA E101. 2. Pumping unit shall have a head-capacity curve which is continuously decreasing within

the operating range from shutoff head to maximum capacity. 3. Pumping unit shall be stable, free from vibration and cavitation throughout the

operating range specified herein. Pumping units having a head-capacity curve which has a flat or reverse slope will not be accepted.

B. Finite Element Analysis (FEA): Perform a FEA of the drive motor mounted on the pump discharge head to determine the first reed critical frequency of the combined motor/discharge head structure in two perpendicular directions. 1. Discharge head shall be modeled in shell elements or solids. 2. Motor shall be modeled using beams elements which duplicate the motor reed critical

frequency data supplied by the motor vendor. 3. All analysis shall be performed using the commercially available FEA code. 4. Discharge head shall be considered mounted to a rigid foundation, with the discharge

nozzle considered free to move if the first reed critical frequency is located above running speed; this will provide a lower bound to the natural frequency.

5. Discharge nozzle shall be considered fixed if the first reed critical frequency is located below running speed; this will provide an upper bound to the natural frequency.

6. Pump discharge head shall be designed so that the combined motor/discharge headfirst reed critical frequency is not within ±20 percent of the operating speed range of the pump. If this is not practical, the pump manufacturer shall perform a forced vibration response to ensure the pump does not exceed vibration limits.

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C. Head Assembly: 1. Type: Above-grade discharge configuration; consisting of discharge elbow, motor

mounting pedestal, base plate, sole plate and flanged discharge connection, designed to support the driver and line column.

2. Material: Fabricated steel, ASTM A36, minimum 3/8-inch thickness. 3. Discharge Elbow: Designed to minimize turbulence and headloss, with a 90 degree

discharge, supported on a flange or base plate. 4. Discharge Flange: As specified in Pump Schedule. 5. Sole Plate: Steel plate, 4 feet by 4 feet by 1.5 inches thick minimum, supporting the

complete pumping unit; drilled and tapped for base plate; having a cutout large enough to remove pumping unit without disturbing the sole plate setting.

6. Connections: Provide a 1/2-inch NPT tap and plug on side of discharge pipe for pressure gauge and 3/4-inch tap for seal water connection in base of head for return to wet well. Provide API seal flush piping plan 13 with 1/2-inch stainless steel tubing from mechanical seal to wet well drain tap in bottom of head.

7. Shaft Seal: Externally mounted cartridge type single mechanical seal with self-aligning and hydraulically balanced seal faces; flush port; metal parts constructed of Type 316 stainless steel and Viton secondary sealing elements; and seal faces of carbon vs. ceramic.

8. Stuffing box shall be constructed for future in-field conversion from mechanical seal to packing.

D. Pump Bowl: 1. Construction: ASTM A-48, Class 30, or higher, and shall be free of blow holes, sand

holes, or other detrimental defects. 2. Bowl shall be lined on the interior and exterior with porcelain or powder epoxy. 3. Pressure Requirements: Capable of withstanding a hydrostatic pressure equal to twice

the pressure at the high head operating condition or 150 percent of the pressure at shutoff head, whichever is greater.

4. Provide a suitable suction bell or flange attached to the lower bowl. 5. All hardware bolts, and nuts on bowl assembly shall be Type 316 stainless steel.

E. Impellers: 1. Provide enclosed type as indicated in Pump Schedule, securely fastened to shaft with

stainless steel keys, taper bushings, or lock nuts for either normal or reverse rotation. 2. Dynamically and statically balanced; individually dynamically balanced so the residual

unbalance does not exceed ANSI S2.19 Grade G6.3. 3. Capable of adjustment vertically by means of an adjustable coupling between the pump

and the driver. 4. Impellers shall be Type 316 stainless steel (per ASTM A743 CF 8M) with no coatings.

F. Wear Rings: 1. A replaceable double wear ring system shall be provided. The wear rings shall be of

the peripheral design. The rings shall be press fit into the pump case and onto the impeller. The casing wear rings shall be constructed of A743 CF 8M stainless steel and heat treated. The impeller wear rings shall be of like material and shall be heat treated to 100 BHN softer or harder than the casing wear ring to reduce galling.

G. Top Shaft: 1. Material: Type 416. 2. Stress and Tolerances: Comply with the requirements of AWWA E101. 3. Shaft size shall be ample to transmit the horsepower required by motor and pump,

minimum 1.5-inch diameter.

H. Line Shaft: 1. Line shafts shall be of Type 416 stainless steel grade (A-582), with a minimum

diameter as listed in pump data sheet, and shall meet the requirements set forth above

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for the pump shafts. Line shafts shall have pump shaft quality dimensional tolerances of + .000” - .002”. The shafts shall be of ample size to operate without distortion or vibration. The top shaft for the pump shall be connected to the motor shaft with a coupling that is: a. Rigid, stainless steel, flanged, adjustable, four piece. b. Split ring and key mounted type. c. Designed to provide a means of adjusting the pump impellers. d. Easily accessible through openings in the motor base and designed to permit

easy dismantling of the coupling. e. 416 stainless steel. f. Fastened with stainless steel bolts and nuts.

2. Shaft Couplings: Threaded type and Type 416 stainless steel. Axial alignments shall be corrected to 0.002-inch in 6 inches.

3. Shaft threads shall be lathe cut and shall be left hand to tighten during pump operation. 4. Furnished in interchangeable sections having a nominal length of 5 feet. First section of

column above the bowl shall not exceed five feet in length.

I. Line Shaft Bearing: 1. The line shaft bearings shall be product lubricated and shall be spaced not more than

five feet apart. The line shaft bearings shall be Neoprene. The bearing retainers shall be 316 stainless steel. The maximum angle error of the thread axis to the bore axis shall be within 0.001-inch per inch of thread length. The concentricity of the bore of the threads shall be within 0.005-inch of the total indicator reading.

J. Discharge Column Pipe: 1. Provide interchangeable pipe sections which are sized in accordance with the

AWWA E101.

K. Ratchets: Provided with a non-reverse mechanism in the motor to protect the line shaft and the motor from reverse rotation when the power is interrupted and the water empties from the discharge column.

2.3 MOTORS

A. Comply with NEMA designation, temperature rating, service factor, enclosure type, and efficiency requirements for motors specified in Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below” for motors, 600 volts and lower. 1. Motor Sizes: Minimum size as indicated, but large enough so driven loads will not

require motor to operate in service factor range above 1.0. a. Motor shall have a sound level of no more than +85 dB-A (average) at a five foot

distance as defined by ANSI Standard Method. b. Motor shall be TEFC and have Service Factor of 1.15. c. Motor shall be premium efficiency and inverter duty. d. Motor shall be vertical solid shaft. e. Motor shall have high thrust bearings. f. Motor shall have space heaters. g. Motor shall have oil lubricated bearings. h. Motor shall have non-reversing ratchet. i. Motor HP shall be sufficient for the pump over entire pump curve.

2. Controllers, Electrical Devices, and Wiring: Comply with requirements for electrical devices and connections specified in Division 16 Sections. a. Motor shall be provided with sensors to monitor the following:

1) Motor winding temperature, High. 3. Requirements of this Section supersede any conflicting requirements of the specified

Division 16 Section.

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2.4 CONTROL PANEL CONSTRUCTION REQUIREMENTS

A. Refer to Section 16486 Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs), for the construction requirements of each Control Panel. All panels specified under this Section shall be submitted as a part of each associated mechanical equipment submittal.

2.5 ACCESSORIES

A. Vortex Suppressor/Basket Suppressor: 1. Provide on suction bell; designed for an approach velocity of 2 ft/sec; constructed of

Type 316 stainless steel. 2. Basket Suppressor: Provide a basket suppressor to prevent vortices from entering the

pump suction bell. a. Screen opening shall be 1/2-inch; select woven wire cloth with a net opening of

65%, bottom shall be solid(no screening). b. Secure to bottom of suction bell with eight Type 316 stainless steel fasteners

having either lock washers or locking nuts.

B. Equipment Identification Plates: A 16-gauge stainless steel identification plate shall be securely mounted on the equipment in a readily visible location. The plate shall bear 1/4-inch die-stamped equipment identification number indicated in this Section and/or on the Drawings.

C. Lifting mechanical instructions: Individual equipment and/or each field disassemble part weighing over 100 pounds shall be provided with mechanical device lifting instructions in the O&M Manual.

D. Anchor Bolts: Provide template, as required, and Type 316 stainless steel anchors in accordance with Section 05501 “Anchor Bolts, Expansion Anchors, and Concrete Inserts” and as shown on the Drawings, including anchor bolts for future pump locations.

E. Initial Supply of Lubricants: Manufacturer shall indicate types, brands, and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment. CONTRACTOR shall provide and install the recommended lubricants and shall comply with all manufacturer recommended procedures.

2.6 FINISH

A. Provide polyurethane, pigmented (over epoxy zinc rich primer and high build epoxy) in accordance with Section 09910 “Painting and Protective Coatings.” Pump shall receive surface preparation, prime coat and finish coat in factory.

B. Machined, polished, and nonferrous surfaces shall be coated with corrosion prevention compound.


A. Factory Tests and Adjustments: 1. Test all pumping unit bowl assemblies, including the discharge head and at least one

section of column, to be furnished. 2. Utilize motors to be furnished or a calibrated factory motor. 3. Include test data sheets, curve test results, performance test logs, certified by a factory

test engineer.

B. Functional Test: Perform motor test on equipment. Include a vibration test, as follows: 1. Dynamically balance impellers of each pump before final assembly.

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C. Performance Test: 1. Test procedures, interpretation and conversion of data shall conform to the latest

requirements of the Test Code of the Hydraulic Institute Standards. 2. Tests shall be sufficient to determine the curves of head, input horsepower, and

efficiency relative to capacity from shutoff to 150% of design flow. A minimum of six points, including shutoff, shall be taken for each test.

3. At least one point shall be obtained as near as possible to each specified condition. 4. Test results shall show no minus tolerance or margin with respect to capacity, total

head, or guaranteed efficiency at the specified conditions. Pumps shall be within the following plus tolerance: +10 percent of rated capacity at rated head and + 6 percent of rated head at rated capacity per HIS 14.6 Grade 1U.

5. Results of the performance test shall be certified by a Registered Professional Engineer and submitted for approval prior to shipment.

D. Hydrostatic Test: Pump casing tested at 150 percent of shutoff head. Test pressure maintained for not less than five minutes.

E. Motor Testing: Perform as required per applicable motor section.

PART 3 - EXECUTION

3.1 GENERAL

A. Install and adjust equipment in accordance with the Drawings, approved shop drawings, and the manufacturer's instructions. Any required field assembly of the pumping unit is to be completed only while the manufacturer’s representative is present at the job site. Do not operate the equipment until the installation is approved by the manufacturer’s representative.

3.2 INSTALLATION

A. The sole plate shall be set to true level using machinist’s level. The tolerance for leveling shall not exceed 2/1000 inch per foot of length along any side of the sole plate. The representative of the pump manufacturer shall be present during the leveling. The pump manufacturer shall certify that the leveling is in accordance with the limits specified herein and is acceptable to the manufacturer.

B. Provide Type 316 stainless steel anchor bolts, washers, and nuts sized as recommended by manufacturer.

C. Provide pipe supports for supporting all piping independently of pump. Provide seal water drain piping into wet well.

D. After the pump and driver have been set in position, aligned, and leveled to the proper elevation, grout the space between the bottom of the sole plate and the concrete foundation with a poured, non-shrinking grout of the proper category, as specified in Section 03600 “Grout”. Remove wedges after grout is set and pack void with grout.

E. Complete equipment installation with controls, safety devices and auxiliary support systems necessary to start the equipment and verify that the equipment functions correctly under no load conditions. Turn rotating equipment by hand to check. Complete cleaning and testing of piping systems. Inspect and clean equipment, devices, piping, and structures of debris and foreign material.

F. Remove temporary bracing supports and other construction debris that may damage equipment.

G. Remove protective coatings and oils used for protection during shipment and installation.

H. Flush, fill, and grease lubricated systems in accordance with Manufacturer's instructions.

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I. Install temporary connections and devices required to fill, operate, checkout and drain the system. Provide temporary valves, gauges, piping, test equipment, and other materials and equipment necessary to conduct testing and startup.

J. Equipment 1. Check equipment for correct direction of rotation and freedom of moving parts. 2. Align equipment to Manufacturer's tolerances. Adjust clearances and torques. 3. Check installation prior to start-up for conformance to Manufacturer's instructions. 4. Adjust or modify equipment to ensure proper operation.

K. Correct any deficiencies or problems noted in Manufacturer's representative's installation reports.


A. Functional Tests: Conduct on each pump as described below and in accordance with Section 01600 “Startup, Testing, Commissioning, and Training”. 1. Alignment: Test complete assemblies for correct rotation, proper alignment and

connection, and quiet operation. 2. Vibration Test:

a. Test units installed and in normal operation, and discharging to the connected piping systems at rates between the low discharge head and high discharge head conditions specified, and with the actual facility structures and foundations provided, shall not develop at any frequency or in any plane, peak-to-peak vibration amplitudes exceeding the limits specified.

b. Limits: Complete rotating assembly, including drive unit and motor, shall be less than limits established in the current version of the Hydraulic Institute Standards.

c. If units exhibit vibration in excess of the limits specified adjust, or modify as necessary. Units which cannot be adjusted or modified to conform as specified shall be replaced.

d. Vibration test results shall be submitted to OWNER for approval. 3. Flow Output: Measured by plant instrumentation or portable meters supplied by

CONTRACTOR.

B. Performance Test: In accordance with Hydraulic Institute Standards. 1. Place each piece of equipment in the system in operation until the entire system is

functioning. All components shall continue to operate without alarms or shut downs, except as intended, for eight consecutive hours to be considered started up.



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1 Installation assistance and inspection. 1 Functional and performance testing. 1 Pre-startup classroom or site training. 1 Facility startup. 2 Post-startup equipment inspection and training of

OWNER’S personnel at 6 months and 12 months after Substantial Completion.

B. Services Provided: 1. Furnish test forms and procedures for field-testing. 2. Furnish startup services. 3. Furnish training of OWNER’S personnel at such times requested by OWNER

C. Manufacturer’s services and training shall comply with the requirements of Section 01600 “Startup, Testing, Commissioning, and Training”.

3.5 FACILITY STARTUP

A. Startup of the facility shall be in accordance with Section 01600 “Startup, Testing, Commissioning, and Training”. After initial startup under the supervision of a qualified representative of the pump manufacturer, a preliminary “running-in” period will be provided for the CONTRACTOR, per the Contract Documents, to make field tests and necessary adjustments. At the end of the specified period of operation, the pumps will be accepted if, in the opinion of the ENGINEER, the pumps has operated satisfactorily without excessive power input, wear, lubrication, or undue attention required for this operation, and if all rotating parts operate without excessive vibration or noise at any operating speed and head, including shutoff.

3.6 SUPPLEMENT


END OF SECTION

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PUMP DATA SHEET Location Plant Water Pump Station Equipment Tag Number(s) PWP-1, PWP-2 Quantity 2 Pump Name Plant Water Pump Service Conditions Liquid Pumped Non-Potable Water Liquid Temperature, °F Max: 90 / Min: 32 Chemicals Injected into Wetwell / Max. Rate n/a Specific Gravity 1.0 Abrasive (Y/N) N Possible Scale Buildup (Y/N) Y Explosion-proof (Y/N) N Continuous Duty (Y/N) Y Performance Requirements Flow at Primary Condition of Service, gpm 425 Total Head at Primary Condition, ft. 200 Minimum Bowl Efficiency at Primary Condition 80% Maximum NPSHR at Min Head Condition, ft 14 Shutoff Head, ft. (approximate) 240 Pump Speed, Maximum, rpm 1800 Motor HP, Maximum 40 Motor Voltage, Phase 480 V, 3-Phase Constant Speed (Y/N) N Adjustable Speed (Y/N) Y Pump Construction Details Impeller Type (Enclosed, Open) / Material Enclosed / 316 Stainless Steel Line Shaft (Enclosed, Open) / Lubrication (Oil, Product) Open / Product Line Shaft Minimum Diameter / Material 1.5 inch / 416 Stainless Steel Motor Shaft: (Solid, hollow) Solid Column Pipe Size / Type 6 inch / Flanged Column Pipe Wall Thickness / Material 0.375 inch / 316 Stainless Steel Discharge Head Construction (Cast Iron, Fab. Steel) Fabricated Steel Discharge Head Size / Pressure Rating 6 inch / 150 lb Hydrostatic Test Pressure (psig) 1.5 times shutoff head Factory Test Certified by Engineer (Yes/No) Yes Field Testing (Required/Not Required) Required

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I&C – GENERAL PROVISIONS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13300 INSTRUMENTATION AND CONTROLS (I&C - GENERAL PROVISIONS.DOCX

SECTION 13300 INSTRUMENTATION AND CONTROLS - GENERAL PROVISIONS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The General Contractor (GC) shall perform all work necessary to select, furnish, configure, customize, program/configure, troubleshoot, install, connect, calibrate, and place into operation all specified equipment and instrumentation hardware/software specified within Division 13.

B. The General Contractor shall procure the services of a pre-qualified Application Services Provider (ASP), as a first-tier subcontractor, who shall perform all work necessary to configure, customize, program/configure, troubleshoot, connect, calibrate and place into operation all specified equipment furnish under this contract. The ASP shall have the qualifications described herein.

C. Items specifically included within the ASPs scope of work, reference Specification Section 13305 for additional details, include the following: 1. Programmable Logic Controller (PLC) programming of PLC-MSB, testing of PLC-MSB

logic, startup/training activities associated with the programmed portion of the PLC-MSB.

2. Startup activities associated with the Vendor Systems (Lime System, Belt Filter Press Systems, Polymer System and Belt Filter Sludge Feed Systems).

3. Human Machine Interface (HMI) graphics development, HMI software configuration, database development, report development, and startup/training activities associated with the configured portions of the HMI system.

D. All bidders shall visit the site of the project, prior to submitting a bid, and satisfy themselves as to any question that they may have relating to existing equipment, condition or construction.

E. The GC’s work shall include furnishing, installing and testing the equipment and materials detailed in the following Sections:

Section No. Title

13302 Instrumentation & Controls (I&C) – Testing 13303 I&C – Training 13305 I&C – Application Services 13310 I&C – Flow Devices 13312 I&C – Level Devices 13314 I&C – Pressure Devices

13318 I&C – Analyzer Devices 13320 I&C – Fiber Optic Data Network

13325 I&C – Control Panels 13327 I&C – Panel Mounted Equipment 13345 I&C – Instrumentation Support Hardware 13400 I&C – Process Control Descriptions 13410 I&C – Field Instrument List

13515 I&C – Communications Interface Equipment

F. Requirements specified in this Section apply to all equipment specified in the above Sections, unless otherwise stated.

G. The Flower Mound WWTP is an existing plant, and all work shall be coordinated with its operating personnel to minimize impact on daily operation.

H. The Owner shall retain salvage rights to all materials and equipment removed in the course of this work. All materials and equipment retained by the Owner shall be delivered to a plant site

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location designated by the Owner. Any material or equivalent not retained by the Owner shall be removed from the site and disposed of by the GC in accordance with applicable regulation and laws.

I. The GC shall coordinate with the Owner, Engineer and ASP, for all scheduling, installation, testing, startup and training services.

J. The work shall include furnishing, installing and testing of the equipment and materials detailed in each of the Division 13 Instrumentation and Controls Specification Sections.

K. Instrumentation specified in other Divisions shall meet the requirements of the Instrumentation and Controls Sections of Division 13.

L. The GC shall coordinate his construction schedule and Instrumentation and Controls interface with the suppliers of Instrumentation and Controls equipment specified under other Divisions.

M. The GC shall provide a monthly status report and updated overall project schedule. The GC shall arrange their overall project schedule to accommodate the requirements for the testing by the ASP.

N. Several Vendor package systems are being provided under other sections of this contract and will interface with the Control System via Ethernet communications or via hard-wired inputs and outputs. Refer to the associated specification sections and the contract drawings for details. The GC, with assistance with the ASP, shall be responsible for coordination, purchasing, installing, and configuring any communication devices and/or software drivers necessary to ensure that the Control System can communicate with each of the vendor-furnished systems.

O. Where specified herein and/or on the contract drawings, specific instruments and field devices provided by Vendor packaged systems are being provided by each vendor and shall be installed by the GC according to vendor instructions. The Vendor supplier shall provide the instruments and mounting hardware and will supervise installation. Upon satisfactory completion of installation, the GC and ASP shall coordinate with each vendor to inspect finished work. The GC shall submit to the Engineer written documentation indicating that each vendor has inspected and approved the installation.

P. The work shall also include the following: 1. Make connections, including field connections and interfacing between

instrumentation, controllers, control devices, control panels and instrumentation furnished under other Divisions.

2. Integrate equipment furnished as a part of other Divisions, and shown on the Contract Drawings, into the overall Instrumentation and Control System according to the requirements of Division 13.

3. Make wiring terminations for all field-mounted instruments furnished and installed under other Divisions, including process instrumentation primary elements, transmitters, local indicators and control panels. Install vendor-supplied cables specified under other Divisions.

4. Auxiliary and accessory devices that are necessary to perform the intended system operations or to interface with existing equipment or equipment provided by other suppliers under other Sections of these specifications, shall be included whether or not they are shown on the Drawings. These devices include, but are not limited to, transducers, current isolators, signal conditioners, interposing relays and protocol converters.

5. System design shall allow for removal of individual devices from service without disrupting other unrelated devices in service.

6. Equipment shall be fabricated, assembled, installed, and placed in proper operation in full conformity with detail drawings, specifications, engineering data, instructions, and recommendations by the equipment manufacturer as approved by the Engineer.

7. Furnish equipment which is the product of one manufacturer to the maximum extent possible. Where this is not practical, all equipment of a given type shall be the product

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of one manufacturer. All materials, equipment, labor, and services necessary to achieve the monitoring and control functions described herein shall be provided in a timely manner so that the monitoring and control functions are available when the equipment is ready to be placed into service.

8. Provide all instrumentation relocation work associated with the relocation of equipment for the existing and new facilities, including disconnecting all existing wiring and conduits and terminating, calibrating and placing into service the relocated equipment.

9. Coordinate the sequence of demolition with the sequence of construction to maintain plant operation in each area. Remove and demolish equipment and materials in such a sequence that the existing and proposed plant will function properly with no disruption of treatment.

10. Modifications to existing instrumentation and control systems as required to new and existing equipment to maintain the plant in operation.

11. The work shall include furnishing, installing, landing and testing of all fiber optic data communications cables and connectors as detailed under specification Section 13320.

12. Furnish all fiber optic and specialty cable systems necessary to make the correct connections to the fiber optic patch panels (FOPPs) as shown in the Contract Drawings. The GC and ASP shall coordinate the landing and proper labeling of all fiber cables and all individual fibers within Fiber Optic Patch Panels.

13. Install the fiber optic cables in accordance with the manufacturer’s installation instructions. Review and coordinate the conduit and/or raceway layout and construction sequencing, prior to installation, with the cable manufacturer to ensure conduit and/or raceway compatibility with the systems and materials being furnished.

14. New Lime Stabilization System Control Panel (PLC-SSCP) - A new Lime Stabilization System Control Panel (SSCP) is being provided to monitor and control the Lime Feed Systems, conveyors, and other miscellaneous equipment. The GC shall provide and install a new fiber optic cable (FOC-SSCP) between the new SSCP control panel and the existing Network Rack located in the Plant Pump Building MCC Room. During the submittal and construction phase, the GC shall coordinate with the SSCP vendor to provide sufficient room within the PLC-SSCP panel for the FOPP-SSCP and ESW-SSCP equipment. During field installation and startup, the SSCP vendor shall coordinate with the GC to allow the GC to provide, install and make operational the FOPP-SSCP and ESW-SCCP equipment within the SSCP Control Panel.

15. Gas Alarm Control Panel (GAP) - Provide a new GAP enclosure to house Gas detection equipment and miscellaneous equipment. The GAP enclosure will be connected with the two Beacon/Horn Control Panels.

16. Plant Water Low Level Relay Panel (LLRP-PW) - Provide a new Low Level Relay Panel to be located within the Plant Pump Building MCC Room. The LLRP-PW will be wired to the new Plant Water Pumps and existing PLC-MSB as shown in the Contract Drawings. The GC shall provide all new terminations, interposing relays, etc. as required for the new field I/O being added to PLC-MSB.

17. Belt Filter Press Control Panels (PLC-BFP1 and PLC-BFP2) - New Belt Filter Press Control Panels are being provided, by others, to monitor and control the Belt Filter Presses. The new Belt Filter Press Control Panels will house PLC racks, and miscellaneous equipment. The design intent is to re-utilize the existing Ethernet cables to re-establish communication.

18. Plant Pump Building (PLC-MSB) - Provide modifications to the existing PLC-MSB to include new I/O modules as shown in the Contract Drawings. The GC shall provide all new terminations, interposing relays, analog surge suppression, etc. as required for the new field I/O being added to PLC-MSB.

1.2 RELATED WORK

A. All equipment and work provided under any division of these specifications shall fully comply with the requirements of Division 13 Instrumentation Sections.

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B. Partial Control System Architecture Diagram is included in the Drawings.

1.3 SUBMITTALS

A. General submittal requirements include: 1. Refer to Section 01330 for general submittal requirements. 2. Refer to all other Division 13 I&C Sections for all additional specific submittal

requirements. 3. Shop drawings shall be submitted as detailed herein. Shop drawings shall

demonstrate that the equipment and services to be furnished comply with the provisions of these specifications and shall provide a complete record of the equipment as manufactured, delivered, installed and placed in service.

4. Submittals shall be complete and shall give equipment specifications, details of connections, wiring, ranges, installation requirements, and specific dimensions. Submittals consisting of only general sales literature shall not be acceptable.

5. Submittals shall be bound in separate three-ring binders, with an index and sectional dividers, and with all included drawings reduced to a maximum size of 11-inches by 17-inches, then folded to 8.5-inches by 11-inches for inclusion inside the binder. Maximum binder thickness shall be 3 inches.

6. The shop drawings title block shall include, as a minimum, the GC's registered business name and address, Owner and project name, drawing name, revision level, and shall identify personnel responsible for the content of the drawing.

7. Incomplete or partial submittals not complying with the submittal requirements outlined in this Section will be returned without review.

8. Separate submittals as listed in the table below shall be made.

Submittal Number Submittal Title Submittal Number

Description and Requirements

Location/Governing Specifications

1

Project Plan, Schedule, and Deviation List

This submittal shall be submitted and approved before any

additional submittals will be accepted.

13300-001 13300

2 Input/Output (I/O) List 13300-002 13300

3 Field Instruments 13300-003 13310, 13312, 13314, 13318, 13410

4 Hardware and Software Packages 13300-004 13325, 13327, 13345, 13515

5 Panel Layout Drawings, Wiring

Diagrams and Loop Wiring Diagrams

13300-005 13300, 13325

6 Testing Plan 13302-001 13300, 13302, 13305

7 Training Plan 13303-001 13303

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Submittal Number Submittal Title Submittal Number

Description and Requirements

Location/Governing Specifications

8

Spares, Expendables, and Test Equipment.

All spares in the listed Sections shall be included in a single

submittal.

13300-006

13300, 13310, 13312, 13314, 13318, 13320, 13325, 13327, 13345,

13515

9 Final System Documentation Per O&M Submittal Numbering 01730, 13300, 13305

10 Fiber Optic Cabling and Equipment 13320-001 13320

B. Project Plan, Schedule and Deviation List Submittal 1. Submit, as soon as possible following GC’s receipt of Notice to Proceed, a Project

Plan, Schedule and Deviation List Submittal. The Project Plan, Schedule and Deviation List Submittal shall be submitted and favorably approved before any further submittals will be accepted and prior to scheduling of the first GC coordination meeting. The Project Plan, Schedule and Deviation List Submittal shall, as a minimum, contain the following: a. Overview of the Process Control System, clearly describing the GC’s

understanding of the project work and interfaces to other systems; and including a preliminary system architecture drawing and proposed project work schedule detailing all GC’s work activities.

b. Approach to work clearly describing how the GC intends to execute the work, including detailed discussion of switchover, startup, replacement of existing equipment with new, and other tasks as required by these specifications as applicable.

c. Preliminary PLC hardware submittal information shall be included solely for determining compliance with the requirements of the Contract Documents prior to beginning development of application programming. Review and approval of software and hardware systems as part of this Project Plan stage shall not relieve the GC of meeting all the functional and performance requirements of the system as specified herein. Substitution of manufacturer or model of these systems after the submittal is approved shall not be permitted without prior Engineer approval.

d. Details of personnel assigned to the project and organizational structure including the GC’s project manager, project engineer, and lead project technicians. Include resumes of each key individual and specify in writing their commitment to this project.

e. Preliminary coordination meeting agendas as specified herein. f. Preliminary training plan g. Samples of shop drawings to be submitted in conformance with the requirements

of the Specifications shall be submitted. At a minimum include samples of panel fabrication drawings, loop, and I/O wiring diagrams.

2. Exceptions to the Specifications or Drawings shall be clearly defined in a separate Deviation List. The Deviation List shall consist of a paragraph by paragraph review of the Specifications indicating acceptance or any proposed deviations, the reason for exception, the exact nature of the exception and the proposed substitution so that an evaluation may be made by the Engineer. The acceptability of any device or methodology submitted as an "equal' or "exception" to the specifications shall be at the sole discretion of the Engineer. If no exceptions are taken to the Specifications or Drawings, the GC shall make a statement indicating so. If there is no statement

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included by the GC, it shall be interpreted by the Engineer to mean that no exceptions are taken.

3. A Project Schedule shall be prepared and submitted using Microsoft Project. The schedule shall be prepared in Gantt chart format clearly showing task linkages for all tasks and identifying critical path elements. The GC’s schedule shall be based on and coordinated with the ASP schedules and must meet all field installation, testing, and startup milestones in those schedules.

4. The GC schedule shall illustrate all major project milestones including the following: a. Schedule for all subsequent project submittals. Include in the time allotment the

time required for General Contractor submittal preparation, Engineer's review, and a minimum of two complete review cycles.

b. Proposed dates for all required project Coordination Meetings and workshops. c. Hardware purchasing, fabrication, and assembly (following approval of related

submittals) d. Software purchasing and configuration (following approval of related submittals) e. Shipment of all instrumentation and control system equipment f. Installation of all instrumentation and control system equipment g. Duration and dates for all required testing activities. Testing schedule shall include

submittal of test procedures a minimum of 30 days prior to commencement of testing. Schedule shall also include submittal of completed documentation of testing activities for review and approval by the Engineer prior to equipment shipment, startup, or subsequent project work.

h. The GC shall arrange the schedule to accommodate the requirements of the ASP to develop, test, troubleshoot, and train the Owner’s staff on the PLC and HMI application and systems. The timing of these coordination efforts shall be determined by the ASP; however, the GC shall include all necessary costs to accommodate the minimum time slots in their overall project schedule. All time allotments shall exclude any legal holidays, or days lost due to delays caused by the GC.

i. Include a schedule for system cutover, startup, and/or placing in service for each major system. At a minimum, include the schedule for each process controller modified or provided under this Contract.

j. Schedule for all training including submittal and approval of O&M manuals, factory training, and field training

C. Input/Output (I/O) List Submittal 1. The ASP shall develop and submit the system I/O list that includes all I/O identified in

the project drawing P&IDs. Submittal shall be a complete system I/O list for all equipment connected to the control system under this Contract.

2. The I/O list shall be submitted in both a Microsoft Excel readable electronic file format on a CD-ROM and an 8-1/2 inch by 11-inch hard copy.

3. The I/O list shall reflect all active and spare I/O points. Add points to accommodate spare I/O.

4. The I/O list shall be arranged such that each control panel has a dedicated worksheet. At a minimum, I/O worksheet tables shall include the following information: a. TAG NUMBER(S): The identifier assigned to a device that performs a function in

the control system. As part of this information, the loop number of the tag shall be broken out to allow for sorting by loop.

b. DESCRIPTION: A description of the function of the device (text that includes signal source, control function, etc.) Include the text "Spare Points" for all I/O module points that are not connected to equipment.

c. PHYSICAL LOCATION: The Control Panel designation of where the I/O point is wired to.

d. Physical POINT ADDRESS: Rack, Slot, and Point (or Channel) assignment for each I/O point.

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e. LOGICAL POINT ADDRESS: Since the ASP is performing the programming on the project, then leave this field blank for use by the ASP.

f. I/O TYPE: use DO - Discrete Output, DI - Discrete Input, AO - Analog Output, AI - Analog Input, PI - Pulse Input, or PO – Pulse Output.

g. RANGE/STATE: The range in engineering units corresponding to an analog 4-20 mA signal, or, the state at which the value of the discrete points is "1."

h. ENGINEERING UNITS: The engineering units associated with the Analog I/O. i. ALARM LIMITS: Include alarm limits based on the control descriptions and the

Drawings. j. P&ID – the P&ID or drawing where the I/O point appears on. Mark as "NA" (Not

Applicable) if the I/O point is derived from a specification requirement and is not on the P&IDs.

5. The I/O list shall be sorted in order by: a. Physical location b. I/O Type c. Loop Number d. Device Tag

6. Once the I/O List is approved, the PLC I/O addresses may not be modified without approval by the Engineer and ASP.

7. Where multiple mechanical components are provided for process redundancy, their field connections to I/O modules shall be arranged such that the failure of a single I/O module will not disable all mechanical components of the redundant system. This applies to all I/O types.

D. Field Instruments Submittal 1. Submit complete documentation of all field instruments using ISA-S20 data sheet

formats. Submit a complete Bill of Materials (BOM) or Index that lists all instrumentation equipment organized according to the loop numbering system as shown in the Contract Documents.

2. Submit separate data sheets for each instrument including: a. Plant Equipment Number and ISA tag number according to the Drawings b. Product (item) name used herein and on the Contract Drawings c. Manufacturer's complete model number d. Location of the device e. Input - output characteristics f. Range, size, and graduations in engineering units g. Physical size with dimensions, enclosure NEMA classification and mounting

details in sufficient detail to determine compliance with the requirements of the Contract Documents

h. Materials of construction for enclosure and wetted parts i. Instrument or control device sizing calculations where applicable j. Certified calibration data for all flow metering devices k. Two-wire or four-wire device type, as applicable

3. Submit index and data sheets in electronic format as well as hard copies on 8 1/2" x 11" formats. Electronic format shall be in Microsoft Excel or Word. Submit electronic copy on CD-ROM or DVD.

E. Hardware and Software Packages Submittal 1. For each hardware component indicated below, submit a cover page that lists, at a

minimum, date, specification number, product name, manufacturer, model number, Location(s), and power required. Preferred format for the cover page is ISA S20, general data sheet; however, other formats will be acceptable provided they contain all required information.

2. Catalog cuts for supplied Programmable Logic Controller (PLC), process controller equipment, including central processing units, memory, input modules, output modules, modems, network interface modules, mounting racks, and power supplies.

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Submit descriptive literature for each hardware component that fully describes the units being provided. Any deviation of the hardware systems from the preliminary hardware submittal included in the Process Plan shall be described in detail.

3. Catalog cuts for power supplies, and all other hardware being provided. Submit descriptive literature for each hardware component, which fully describes the units being provided.

4. Complete system architecture diagram showing in schematic form, the interconnections between major hardware components including control centers, panels, power supplies, consoles, computer and peripheral devices, networking equipment, processors, I/O modules, local operator interfaces, and like equipment. The system architecture shall not be a copy of the Contract Document system SCADA Architecture Drawing; it shall be complete and shall depict all required cables, media type between components, network protocol used at each network level, details on connection requirements such as cable pin-outs, port numbers, and rack slot numbers. The intent of this specification requirement is for the ASP to develop a new diagram that is complete in every aspect to allow purchase of all required equipment by part number, and to allow a qualified technician to interconnect all equipment without having to refer to additional manuals or literature. Minimum sheet size shall be 11" x 17", and using a larger sheet size or more than one sheet is acceptable.

5. Submit details of field instrument, valve, power monitoring, and field device digital networks. Submittal shall include details of the field device digital networks technology including type, power requirements, wiring requirements, configuration details, device addressing, and interface to the process control system. Include separate details of the field device digital network configuration(s) for each field level digital network and sub-network.

F. Panel Layout Drawings, Wiring Diagrams and Loop Wiring Diagrams Submittal 1. Where direct hardwired interfaces exist between the GC control panels and vendor

provided control panels furnished under other Divisions, the GC shall provide complete wiring diagrams showing all wiring connections in the I/O system. This includes but is not limited to terminal block numbering, relay contact information, instruments, equipment, and control panel names. These drawings will be included in the Final Documentation submittal. Leaving this information blank on the Final Documentation drawings is not acceptable.

2. Panel Layout Drawings: Drawings shall be furnished for all panels, consoles, and equipment enclosures specified. Panel assembly and elevation drawings shall be drawn to scale and detail all equipment in or on the panel. Panel drawings shall be 11"x17" minimum in size. As a minimum, the panel drawings shall include the following: a. Interior and exterior panel elevation drawings to scale b. Nameplate schedule c. Conduit access locations d. Panel construction details e. Include cabinet assembly and layout drawings shown drawn to scale. The

assembly drawing shall include a bill of material on the drawing with each panel component clearly defined. The bill of material shall be cross-referenced to the assembly drawing so that a non-technical person can readily identify any component of the assembly by manufacturer and model number.

f. Fabrication and painting specifications including color (or color samples) g. Submit construction details, NEMA ratings, intrinsically safe barrier information,

gas sealing recommendations, purging system details, etc. for panels located in hazardous locations or interfacing to equipment located in hazardous areas.

h. Heating and cooling calculations for each panel supplied indicating conformance with cooling requirements of the supplied equipment and environmental conditions. Calculations shall include the recommended type of equipment required for both heating and cooling.

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i. Submit evidence that all control panels shall be constructed in conformance with UL 508 and bear the UL seal confirming the construction. Specify if UL compliance and seal application shall be accomplished at the fabrication location or by field inspection by UL inspectors. All costs associated with obtaining the UL seal and any inspections shall be borne by the GC and included in the Project Bid Price.

3. Panel Wiring Diagrams: Panel wiring diagrams depicting wiring within and on the panel as well as connections to external devices. Equipment external to the control panel and related external connections do not need to be shown on the Panel Wiring Diagrams. Panel wiring diagrams shall include power and signal connections, UPS and normal power sources, all panel ancillary equipment, protective devices, wiring and wire numbers, and terminal blocks and numbering. Field device wiring shall include the device ISA-tag and a unique numeric identifier. The diagrams shall identify all device terminal points that the system connects to. Wiring labeling used on the drawings shall match that shown on the Contract Documents or as developed by the GC and approved by the Engineer. I/O wiring shall be numbered with rack number, slot number, and point number. Two-wire and four-wire equipment shall be clearly identified and power sources noted. Submit final wire numbering scheme. Panel drawings shall be 11" x17" minimum in size.

4. ISA Loop Wiring Diagrams: Detailed ISA loop wiring diagrams showing requirements for each loop which is shown on the contract drawings. The Loop Drawings shall be prepared in accordance with ISA Standard S5.4 latest edition with the layout following Figures 5 and 6 (shown in the S5.4 Standard), titled Minimum Required Items Plus Optional items". Loop drawings shall be 11"x17" minimum in size. The information required on the Loop Drawings in order to satisfy the "minimum" and "optional" requirements is as follows: a. Minimum Required Items – The following information shall be provided on Loop

Drawings in order to meet this requirement: 1) Identification of the loop and loop components shown on the P&IDs. Other

principal components of the loop to be shown and identified under ISA-5.1, "Instrumentation Symbols and Identification"

2) Word description of loop functions within the title. If not adequate, use a supplemental note. Identify any special features or functions of shutdown and safety circuits.

3) Indication of the interrelation to other instrumentation loops, including overrides, interlocks, cascaded set points, shutdowns and safety circuits.

4) All point-to-point interconnections with identifying numbers or colors of electrical cables, conductors, pneumatic multitubes, and individual pneumatic and hydraulic tubing. This identification of interconnections includes junction boxes, terminals, bulkheads, ports, and grounding connections.

5) General location of devices such as field, panel, auxiliary equipment, rack, termination cabinet, cable spreading room, I/O cabinet, etc.

6) Energy sources of devices, such as electrical power, air supply, and hydraulic fluid supply. Identify voltage, pressure, and other applicable requirements. For electrical sources, identify circuit or disconnect numbers.

7) Process lines and equipment sufficient to describe the process side of the loop and provide clarity of control action. Include what is being measured and what is being controlled.

8) Actions or fail-safe positions (electronic, pneumatic, or both) of control devices such as controllers, switches, control valves, solenoid valves, and transmitters (if reverse- acting). These are to be identified in accordance with ISA-5.1, "Instrumentation Symbols and Identification".

9) References to equipment descriptions, manufacturers, model numbers, hardware types, specifications or data sheets, purchase order numbers.

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10) Signal ranges and calibration information, including set point values for switches, and alarm and shutdown devices.

G. Testing Submittals 1. Test Procedures: Submit the procedures proposed to be followed for each test.

Procedures shall include test descriptions, forms, and checklists to be used to control and document the required tests. Include sign-off forms for each testing phase or loop with sign-off areas for the GC, Engineer, and Owner. Refer to Section 13302 for specific testing requirements, and submit separate procedures for each specified test phase including: a. Operational Readiness Test (ORT) b. Functional Demonstration Test (FDT) c. 30-Day Site Acceptance Test (SAT)

2. Test Documentation: Upon completion of each required test, document the test by submitting a copy of the signed off test procedures. Testing shall not be considered complete until the signed-off test procedures have been submitted and favorably reviewed. Submittal of other test documentation, including "highlighted" wiring diagrams with field technician notes, are not acceptable substitutes for the formal test documentation.

3. Each loop shall have a Loop Status signoff form to organize and track its inspection, adjustment and calibration. These forms shall include the following information and check-off items: a. Project Name b. Loop Number c. Detailed test procedure indicating exactly how the loop will be tested including all

required test equipment, necessary terminal block numbers, and simulation techniques required.

d. Tag Number for each component. e. Check-offs/sign-offs for each component:

1) Tag/identification 2) Installation 3) Termination - wiring 4) Termination - tubing 5) Calibration/adjustment

f. Check-off/sign-off space for each loop: 1) Panel interface terminations 2) I/O interface terminations 3) I/O signal operation 4) Inputs/outputs operational: received/sent, processed, adjusted 5) Total loop operation 6) Space for comments. 7) Sign off and date fields for the General Contractor, the Engineer, and the

ASP. 4. Each active analog subsystem element shall have a Component Calibration form.

These forms shall have the following information including space for data entry: a. Project Name b. Loop Number c. ISA Tag Number and I/O Module Address d. Manufacturer e. Model Number/Serial Number f. Summary of Functional Requirements, for example:

1) For Indicators: Scale ranges 2) For Transmitters/Converters: Scale and chart ranges 3) For Computing Elements: Function 4) For Controllers: Action (direct/reverse) control modes (PID)

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5) For Switching Elements: Unit range, differential (fixed/adjustable), reset (auto/manual)

6) For I/O Modules: Input or output g. Calibrations, for example:

1) For Analog Devices: Required and actual inputs and outputs at 0, 25, 50, 75 and 100 percent of span.

2) For Discrete Devices: Required and actual trip points and reset points. 3) For Controllers: Mode settings (PID). 4) For I/O Modules: Required and actual inputs or outputs for 0, 50 and 100

percent of span. h. Space for comments i. Sign off and date fields for the General Contractor, the Engineer, and the ASP.

H. Training Plans 1. Refer to Section 13303 for specific training requirements.

I. Spares, Expendables, and Test Equipment 1. This submittal shall include for each subsystem:

a. A list of, and descriptive literature for, spares, expendables, and test equipment as specified under Division 13 specifications

b. A list of, and descriptive literature for, additional spares, expendables, and test equipment recommended by the manufacturer

c. Unit and total costs for the additional spare items specified or recommended for each subsystem.

J. Final System Documentation 1. The Final System Documentation shall consist of operations and maintenance

manuals as specified herein. The manuals shall be bound in three-ring binders, maximum size of three inches, with Drawings reduced to 11 inch by 17 inch, then folded to 8.5 inch by 11 inch for inclusion. Each section shall have a uniquely numbered tab divider, and each component within each section shall have a separate binder tab divider.

2. The operations and maintenance manuals shall, at a minimum, contain the following information: a. Table of Contents

1) A Table of Contents shall be provided for the entire manual with the specific contents of each volume clearly listed. The complete Table of Contents shall appear in each volume.

b. Instrument and Equipment Lists 1) The following lists shall be developed in Excel and provided not only as a

hardcopy in O&M but also electronically on a CD. 2) An instrument list for all devices supplied including tag number, description,

specification section and paragraph number, manufacturer, model number, serial number, range, span, location, manufacturer phone number, local supplier name, local supplier phone number, completion year replacement cost, and any other pertinent data.

3) An equipment list for all non-instrument devices supplied listing description, specification section and paragraph number, manufacturer, model number, serial number, location, manufacturer phone number, local supplier name, local supplier phone number, completion year replacement cost, and any other pertinent data.

c. Data Sheets with Vendor Operations and Maintenance Information 1) ISA S20 data sheets shall be provided for all field instruments. 2) Cover page for each device, piece of equipment, and OEM software that

lists, at a minimum, date, specification number, product name, manufacturer, model number, Location(s), and power required. Preferred format for the

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cover page is ISA S20, general data sheet; however, other formats will be acceptable provided they contain all required information.

3) Final vendor O&M documentation for each device, piece of equipment, or OEM software shall be either new documentation written specifically for this project, or modified standard vendor documentation. All standard vendor documentation furnished shall have all portions that apply clearly indicated with arrows or circles. All portions that do not apply shall be neatly lined out or crossed out. Groups of pages that do not apply at all to the specific model supplied shall be removed.

4) For any component requiring dip switch settings or custom software configuration, that information shall be included along with the corresponding data sheets and O&M information.

d. As-Built Drawings 1) Complete As-built Drawings, including all Drawings and diagrams specified

in this Section under the "Submittals" paragraph. These Drawings shall include all termination points on all equipment the system in connected to.

2) As-built documentation shall include information from submittals, as described in this Specification, updated to reflect the as-built system. Any errors in or modifications to the system resulting from the Factory and/or Functional Acceptance Tests shall be incorporated in this documentation.

e. Original Licensed Software 1) Submit original software diskettes or CD-ROMs for all software provided

under this Contract. Submit original documentation, both hard copies and in electronic format, for all software provided. Submit license agreement information including serial numbers, license agreements, User Registration Numbers and related information. All software provided under this Contract shall be licensed to the Owner at the time of purchase. Provide media in original packages provided by manufacturer.

f. Electronic O&M Information 1) In addition to the hard copy of O&M data, provide an electronic version of all

equipment manuals CD-ROM or DVD. Electronic documents shall be supplied in Adobe Acrobat format.

2) Provide electronic files for all custom-developed manuals. Text shall be supplied in both Microsoft Office format and Adobe Acrobat format.

3) Provide electronic files for all drawings produced. Drawings shall be in AutoCAD 2007 ".dwg" format and in Adobe Acrobat format. Drawings shall be provided using the AutoCAD eTransmit feature to bind external references, pen/line styles, and fonts into individual zip files along with the drawing file.

4) Each computer system hardware device shall be backed up onto CD-ROM or DVD after Substantial Completion and shall be turned over to the Owner.

5) If specified in the training section, provide digital copies of all training videos. Videos shall be in a format that is readable by standard DVD players and by standard PC DVD drives. Format and shall be a minimum of 800 by 600 pixels and shall include sound.

3. The cover and edge of each volume shall contain the following information: Project Name (refer to Contract Documents) Contract Number (refer to Contract Documents) Instrumentation and Control Systems Hardware [or Applications Engineering] Operations and Maintenance Manual Specification Sections _____, _____, ______ Subcontractor Name Date Volume X of Y (Where X is the volume number and Y is the number of volumes)

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1.4 REFERENCE CODES AND STANDARDS

A. Instrumentation equipment, materials and installation shall comply with the National Electrical Code (NEC and with the latest edition of the following codes and standards: 1. National Electrical Safety Code (NESC) 2. Occupational Safety and Health Administration (OSHA) 3. National Fire Protection Association (NFPA) 4. National Electrical Manufacturers Association (NEMA) 5. American National Standards Institute (ANSI) 6. Insulated Cable Engineers Association (ICEA) 7. The International Society of Automation (ISA) 8. Underwriters Laboratories (UL) 9. UL 508, the Standard of Safety for Industrial Control Equipment 10. UL 508A, the Standard of Safety for Industrial Control Panels 11. UL 50, the Standard of Safety for Enclosures for Electrical Equipment. 12. NFPA 79, Electrical Standard for Industrial Machinery 13. Factory Mutual (FM) 14. All equipment and installations shall satisfy applicable Federal, State, and local codes.

B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

C. All material and equipment, for which a UL standard exists, shall bear a UL label. No such material or equipment shall be brought onsite without the UL label affixed.

D. If the issue of priority is due to a conflict or discrepancy between the provisions of the contract documents and any referenced standard, or code of any technical society, organization or association, the provisions of the contract documents shall take precedence if they are more stringent or presumptively cause a higher level of performance. If there is any conflict or discrepancy between standard specifications, or codes of any technical society, organization or association, or between laws and regulations, the higher performance requirement shall be binding on the General Contractor, unless otherwise directed by the Owner and/or Engineer.

E. In accordance with the intent of the contract documents, the General Contractor accepts the fact that compliance with the priority order specified shall not justify an increase in contract price or an extension in contract time nor limit in any way, the General Contractor's responsibility to comply with all laws and regulations at all times

F. All control panels shall be constructed and the labeling shall be affixed in a UL 508 facility.

1.5 APPLICATION SERVICES PROVIDER (ASP)

A. The GC shall provide an Application Services Provider (ASP) for PLC and HMI application programming and other services as specified in this division and other related divisions.

B. ASP Qualifications 1. The ASP shall perform all work necessary to configure, customize, debug, install,

connect, and place into operation all HMI software specified within this division and other related divisions.

2. The ASP shall provide 24-hour Service Contract for the length of the warranty period a. The service contract requirements shall include telephone support as far as

possible. If necessary, ASP shall provide on-site support for correction of any errors and/or omissions in order to fully meet all requirements of the Contract Documents.

3. The ASP shall coordinate all scheduling, installation, training and startup services with the GC.

4. For the purposes of this and other applicable divisions, the ASP shall be an organization that complies with all of the following criteria:

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a. Holds an adequate Certificate of Insurance for the project work specified herein and in other related sections

b. Employs personnel who have completed and hold certificates for required training c. Employs personnel who have previously completed five projects of this size or

larger in dollar value

C. Only recommended service providers, as listed herein, will be accepted.

D. The ASP shall be the following: 1. Application control Engineering

709 Carlisle Ct. Lake Dallas, TX 75065 Attn: Ron Wise Phone: 214.534.9178

1.6 SIZE OF EQUIPMENT

A. Investigate each space in the structure through which equipment must pass to reach its final location. Coordinate shipping splits with the manufacturer to permit safe handling and passage through restricted areas in the structure.

B. The equipment shall be kept upright at all times during storage and handling. When equipment must be tilted for passage through restricted areas, brace the equipment to ensure that the tilting does not impair the functional integrity of the equipment.


A. Equipment shall be handled and stored in accordance with manufacturer's instructions. Two (2) copies of these instructions shall be included with the equipment at time of shipment, and shall be made available to the General Contractor and Owner.

B. Shipping groups shall be designed to be shipped by truck, rail, or ship. Indoor groups shall be bolted to skids. Accessories shall be packaged and shipped separately.

C. Equipment shall be equipped to be handled by crane. Where cranes are not available, equipment shall be suitable for skidding in place on rollers using jacks to raise and lower the groups.

D. Equipment shall be installed in its permanent, finished location shown on the drawings within seven (7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7) calendar days, the equipment shall not be delivered to the site, but stored offsite, at the General Contractor’s expense, until such time that the site is ready for permanent installation of the equipment.

E. Where space heaters are provided in equipment, provide temporary electrical power and operate space heaters during jobsite storage, and after equipment is installed in permanent location, until equipment is placed in service.

1.8 WARRANTIES

A. Manufacturer’s warranties shall be as specified in each of the Specification Sections.

PART 2 - PRODUCTS – NOT USED

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PART 3 - PART 3 EXECUTION

3.1 GC/ASP PROJECT COORDINATION MEETINGS

A. The GC/ASP shall schedule and administer a minimum of two (2) mandatory Coordination Meetings. The GC/ASP shall make arrangements for meetings; prepare agendas and distribute copies to participants at least one (1) week before scheduled meetings. The meetings shall be held at the General Contractor’s field office at the site and shall include, as a minimum, attendance by the Owner, Engineer, General Contractor’s Project Engineer, ASP Project Engineer, and the Electrical Subcontractor. 1. The first coordination meeting shall be held immediately after the Project Plan

submittal has been submitted and favorably approved in advance of the remaining GC shop drawing submittals (Project Plan and I/O List). The purpose of the first meeting shall be for the GC/ASP to: a. Specific details of System I/O List Submittal. b. Summarize their understanding of the project c. Discuss any proposed substitutions or alternatives and any comments to the

project plan submittal. d. Schedule testing and delivery milestone dates e. Provide a forum for the GC/ASP and Owner to coordinate hardware and software

related issues f. Request any additional information required from the Owner and/or Engineer. g. The GC/ASP shall bring a draft version of shop drawings to the meeting to provide

the basis for the Owner’s and Engineer's input into their development. 2. The second coordination meeting shall be held after the Field Instruments, Hardware

and Software Submittals, and Vendor Submittal packages (Polymer Feed Systems, Lime Stabilization System, Belt Filter Press and Dumpster/Veyor System) has been reviewed by the Engineer and returned to the GC. The purpose of the second meeting shall be to discuss: a. Review comments made on the Vendor Submittal packages. b. Refine scheduled milestone dates. c. Coordinate equipment installation activities. d. Provide a forum for any additional coordination.

3. A typical agenda may include, but shall not be limited to, the following: a. Review minutes of previous meetings b. Review of work progress c. Field observations, problems, and decisions d. Identification of problems which may impede planned progress e. Review of submittal schedule and submittal status f. Review of off-site fabrications and delivery schedules g. Maintenance of progress schedule h. Corrective measures to regain projected schedules i. Planned activities for subsequent work period j. Coordination of projected progress k. Maintenance of quality and work standards l. Effect of proposed changes on progress schedule and coordination m. Other business relating to project work

3.2 GENERAL INSTALLATION

A. Instrumentation and accessory equipment shall be installed in accordance with the manufacturer's instructions. The locations of equipment, transmitters, alarms and similar devices indicated are approximate only. Exact locations of all devices shall be as approved by the Engineer during construction. All information relevant to the placing of process control work shall be obtained in the field. In case of any interference with other work, proceed as directed

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by the Engineer and furnish all labor and materials necessary to complete the work in an approved manner.

B. The P&IDs and Drawings indicate the intent of the interconnection between the individual instruments. Any exceptions should be noted. Two complete sets of approved shop drawings shall be kept at the jobsite during all onsite construction. Both sets shall be marked up identically to reflect any modifications made during field installation or start-up.

C. All equipment used in areas designated as hazardous shall be designed for the Class, Group and Division as required for the locations as shown on the Drawings and specified in Division 16. All work shall be in strict accordance with codes and local rulings.

D. The instrumentation installation details on the Contract Drawings indicate the designed installation for the instruments specified. Where specific installation details are not specified or shown on the Drawings, the American Petroleum Institute (API) Recommended Practice 550 shall be followed as applicable.

E. Unless specifically indicated, direct reading or electrical transmitting instrumentation shall not be mounted on process piping. Instrumentation shall be mounted on instrument racks or stands. All instrumentation connections shall be provided with shutoff and drain valves. For differential pressure transmitters, 5-valve manifolds for calibration, testing and blow down service shall also be provided. For chemical or corrosive fluids, diaphragm seals with flushing connections shall be provided.

F. All piping and tubing to and from field instrumentation shall be provided with necessary unions, calibrations and test tees, couplings, adaptors, and shut-off valves. Process tubing shall be installed to slope from the instrument toward process for gas measurement service and from the process toward the instrument for liquid measurement service. Provide drain/vent valves or fittings at any process tubing points where the required slopes cannot be maintained.

G. Brackets and hangers required for mounting of equipment shall be provided. They shall be installed as shown and not interfere with any other equipment.

H. The shield on each process instrumentation cable shall be continuous from source to destination and be grounded at only one ground point for each shield.

I. Investigate each space in the building through which equipment must pass to reach its final location. If necessary, ship material in sections sized to permit passing through restricted areas in the building. Provide on-site service to oversee the installation, the location and placement of system components, their connections to the process equipment panels, cabinets and devices, subject to the Engineer's approval. Certify that field wiring associated with his/her equipment is installed in accordance with best industry practice. Schedule and coordinate work under this section with that of the electrical work specified under applicable Sections of Division 16.

J. For installations of fiber optic cable within control panel and console assemblies, refer to cable manufacturer's specifications for bend radius. Use cable breakout assembly as recommended by the cable manufacturer. Provide wire basket, strain relief as required to meet manufacturer's strain relief recommendations.

K. Provide local electrical shutoffs and disconnects for all 4-wire field instruments requiring 120 VAC power. Electrical disconnects shall be suitably rated disconnect switches or manual motor starters as specified under Division 16.

L. Provide sun shields for equipment mounted outdoors in direct sunlight. Sunshields shall include standoffs to allow air circulation around the cabinet. Orient equipment outdoors to face North or as required to minimize the impact of glare on LED, LCD, or other digital readouts.

END OF SECTION

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I&C - TESTING Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13302 I&C - TESTING.DOCX

SECTION 13302 INSTRUMENTATION AND CONTROLS - TESTING

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. This Section covers the testing requirements for all devices and systems furnished and installed by the General Contractor (GC), and the Application Services Provider (ASP) as detailed in the Contract Drawings and as described in the related Sections of Division 13.

B. The GC shall provide, jointly with the ASP as required, all labor and materials necessary to coordinate and perform the testing of the Process Control System as specified herein.

C. The GC shall provide all test equipment necessary to perform the testing as specified herein.

1.2 RELATED WORK

A. Refer to Section 13300.

1.3 SUBMITTALS

A. Test Procedure Submittals: Submit the procedures proposed to be followed for each test. Procedures shall include test descriptions, forms, and checklists to be used to control and document the required tests. Include sign-off forms for each testing phase or loop with sign-off areas for the GC, ASP, Engineer, and Owner. Submit separate procedures for each specified test phase including: 1. Operational Readiness Test (ORT). 2. Functional Demonstration Test (FDT). 3. 30-Day Site Acceptance Test (SAT).

B. The system shall be tested using the system architecture Drawing and a BOM of all hardware indicating manufacturer, model, and serial number. The documents for the test plan shall be structured such that the Engineer understands what the inputs are, what the predicted outputs should be and what the actual outputs are.

C. At a minimum, the test plan should include the following: 1. BOM listing control system components. 2. System hardware summary. 3. A testing schedule describing the specific tasks to be performed and the time allotted

for each task. 4. Control Strategy testing. 5. Communications tests to the various PLCs for discrete and analog I/O data transfer. 6. 100 percent I/O point test including all spare points based upon the previously

submitted system I/O list. Provide checklist for verification of each I/O point including spares. The checklist shall include point tag name, description, rack, slot, point and process range (where applicable).

7. Test procedures which shall include test descriptions, forms and checklists to be used to control and document the required tests. Testing shall not start until the Test submittal has been approved.

8. Test documentation which shall include a copy of the signed off test procedures upon completion of each required test.

D. Test Documentation: Upon completion of each required test, document the test by submitting a copy of the signed off test procedures. Testing shall not be considered complete until the signed-off test procedures have been submitted and favorably reviewed. Submittal of other test documentation, including “highlighted” wiring diagrams with field technician notes are not acceptable substitutes for the formal test documentation.

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1.4 TESTS - GENERAL

A. The GC and their Vendors shall test all equipment at his factory prior to shipment. Unless otherwise specified in the individual specification Sections, all equipment provided by the GC shall be tested at the factory.

B. As a minimum, the testing shall include the following: 1. Operational Readiness Tests (ORT) 2. Functional Demonstration Tests (FDT) 3. 30-Day Site Acceptance Tests (SAT)

C. Each test shall be conducted in the cause and effect format. The person performing the test shall initiate an input (cause) and, upon the system's or subsystem's producing the correct result (effect), the specific test requirement shall be satisfied.

D. All tests shall be conducted in accordance with prior Engineer-approved procedures, forms, and check lists. Each test to be performed shall be described and a space provided after it for sign-off by the appropriate parties after its satisfactory completion. The GC shall include “punch list” forms with the test procedures to document issues that arise during the testing. Punch list forms, at a minimum, shall include a specification cross reference; an issue description field; a resolution description field; and a sign-off area for the GC, Owner, Engineer, ASP and Vendor as applicable.

E. Copies of these sign off test procedures, forms, and check lists will constitute the required test documentation. The test result forms shall be submitted to the Engineer for approval within 10 days of completion of each test.

F. Provide all special testing materials and equipment. Wherever possible, perform tests using actual process variables, equipment, and data. Where it is not practical to test with real process variables, equipment, and data, provide suitable means of simulation. Define these simulation techniques in the test procedures.

G. The General Contractor shall coordinate all testing with all affected subcontractors, ASP, Engineer and the Owner.

H. The GC shall furnish the services of field service engineers, all special calibration and test equipment, and labor to perform the factory and field tests.

I. The Engineer reserves the right to test or retest all specified functions, whether or not explicitly stated on the test procedures, as required to determine compliance with the functional requirements of the overall system. Such testing required, to determine compliance with the specified requirements, shall be performed at no additional cost to the Owner. The Engineer's decision shall be final regarding the acceptability and completeness of all testing

J. No equipment shall be shipped to the project site until the Engineer and/or Owner has received all test results and approved the system as ready for shipment in writing.

K. Correction of Deficiencies 1. All deficiencies in workmanship and/or items not meeting specified testing requirements

shall be corrected to meet specification requirements at no additional cost to the Owner. 2. Testing, as specified herein, shall be repeated after correction of deficiencies is made

until the specified requirements are met. This work shall be performed at no additional cost to the Owner.

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PART 2 - PRODUCTS - NOT USED

PART 3 - EXECUTION

3.1 OPERATIONAL READINESS TEST (ORT)

A. Following installation of the process control system components and prior to systems startup and Functional Demonstration Test, the entire system shall be certified (inspected, wired, calibrated, tested, etc., and documented) that it is installed and ready for the ORT as defined below.

B. Loop/Component Inspections and Tests: The entire system shall be checked for proper installation, calibrated, and adjusted on a loop-by-loop and component-by-component basis to ensure that it is in conformance with related submittal's and these Specifications. 1. The Loop/Component Inspections and Tests shall be implemented using Engineer-

approved forms and check lists. Each loop shall have a Loop Status Report to organize and track its inspection, adjustment, and calibration. These reports shall include the following information and check off items with space for sign off by the GC/ASP and Vendor.

2. Project Name, Test Date, GC/ASP/Vendor Name. 3. Loop Number. 4. Tag Number for each component. 5. Check-offs/sign-offs for each component: Tag/identification; installation; termination

(wiring and tubing); scale, range, and set point as applicable; and calibration/adjustment (four-point for analog, set point for switches) rising and falling.

6. Check-offs/sign-offs for the loop: Panel interface terminations; I/O interface terminations; I/O signal operation; inputs/outputs operational (received/sent, processed, adjusted); total loop operation; process controller scaling and adjustment; and space for comments.

7. Each active analog subsystem element and each I/O module shall have a Component Calibration Sheet. These sheets shall have the following information, spaces for data entry, and a space for sign-off by the GC/ASP and Vendor. a. Project Name. b. Loop Number. c. Component Tag Number of I/O Module Number. d. Component Code Number Analog System. e. Manufacturer (for Analog system element). f. Model Number/Serial Number (for Analog system). g. Summary of functional requirements shall include, but not be limited to, scale and

chart ranges of indicators, recorders, and transmitters/converters; functions of computing elements; and parameters of controllers (i.e., proportional, integral, derivative, reverse/forward acting, etc.).

h. Calibrations shall include testing of analog input and output signals at zero, 10, 50, and 100 percent of span. Where appropriate, discrete input signals shall include details regarding actual trip points and reset points.

i. Space for comments. j. Space for sign-off by the GC/ASP and Vendor.

C. The General Contractor shall maintain the Loop Status Reports and Component Calibration Sheets at the job-site and make them available to the Engineer/Owner at any time.

D. These inspections and tests do not require witnessing. However, the Engineer shall review and initial all Loop Status Sheets and Component Calibration Sheets and spot-check their entries periodically and upon completion of the Operational Readiness Test. Any deficiencies found shall be corrected.

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E. Prior to checkout of the I/O to the HMI, the GC, ASP and Vendor shall thoroughly test all I/O from the field device to the PLC terminals, and verify the PLC is powered up and the PLC is communicating to the SCADA servers. After the GC, ASP and Vendor has successfully tested all I/O from the field devices to the PLC terminals, the GC, ASP and Vendor shall test all I/O from the HMI to the field device.

F. Computer-Manual (i.e., Remote-Manual) start/stop, open/close commands of all devices controlled by the SCADA system shall be verified by the GC, ASP and Vendor during the ORT.

G. Upon successful completion of the ORT, the GC, ASP and Vendor shall submit a record copy of the test results to the Owner and Engineer and request the scheduling of the FDT as noted in the following section.

3.2 FUNCTIONAL DEMONSTRATION TEST (FDT)

A. Prior to startup and the 30-day Site Acceptance Test, the entire installed Process Control System shall be certified that it is ready for operation. All preliminary testing, inspection, and calibration shall be complete as defined in the Operational Readiness Tests. The FDT will be a joint test by the GC, ASP and Vendor.

B. Once all process areas have been started up and are operating, a single witnessed Functional Demonstration Test shall be performed on each system to demonstrate that it is operating and in compliance with these Specifications. A Witnessed FDT shall be performed on each process area in a single testing period. The GC shall schedule a minimum of seven (7) to ten (10) work days for each process area. The number of days shall be based on the complexity of the each process area. Each specified function shall be demonstrated on a paragraph-by-paragraph, loop-by-loop, and site-by-site basis.

C. Loop-specific and non-loop-specific tests shall be the same as specified under WFT, except that the entire installed system shall be tested and all functions demonstrated using live field-based data to the greatest extent possible.

D. Updated versions of the documentation specified to be provided for during the tests shall be made available to the Engineer at the job-site both before and during the tests. In addition, one (1) copy of all O&M Manuals shall be made available to the Engineer at the job-site both before and during testing.

E. The daily schedule specified to be followed during the tests shall also be followed during the FDT.

F. The system shall operate for 100 continuous hours without failure before this test shall be considered successful.

G. Punch list items and resolutions noted during the test shall be documented on the Punch list/Resolution form. In the event of rejection of any part or function test procedure, the GC shall perform repairs, replacement, and/or retest within 10 days.

H. Upon successful completion of the FDT, the GC and ASP shall submit a record copy of the test results to the Owner and Engineer and request the scheduling of the SAT as noted in the following section.

3.3 30-DAY SITE ACCEPTANCE TEST (SAT)

A. After completion of the Functional Demonstration Tests, the system shall undergo a 30-day Site Acceptance Test (SAT), under conditions of full plant process operation, without a single non-field-repairable malfunction.

B. During this test, plant operations and GC and ASP personnel shall be present as required to address any potential issues that would impact the overall system operation. The GC and ASP are expected to provide personnel for this test who have an intimate knowledge of the hardware and software of the system. When GC or ASP personnel are not on-site, the GC and/or ASP

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shall provide cell phone/pager numbers that Owner personnel can use to ensure that support staff is available by phone and/or on-site within four hours of a request by operations staff.

C. While this test is proceeding, the Engineer and/or Owner shall have full use of the system. Only plant operating personnel shall be allowed to operate equipment associated with live plant processes. Plant operations shall remain the responsibility of Owner and the decision of plant operators regarding plant operations shall be final

D. Any malfunction during the tests shall be analyzed and corrected by the GC and ASP. The Engineer and/or Owner will determine whether any such malfunctions are sufficiently serious to warrant a repeat of this test.

E. During this 30 consecutive day test period, any malfunction which cannot be corrected within 24 hours of occurrence by GC personnel, or more than two similar failures of any duration, will be considered a non-field-repairable malfunction. Upon completion of repairs by the GC, the SAT will be re-started from the date which the GC successfully corrected the malfunction(s) and the Owner and Engineer have accepted and signed off on the repairs

F. In the event of rejection of any part or function, the GC shall perform repairs or replacement within 10 days.

G. All data base, process controller logic, and graphical interface system errors must be functioning as required per the specifications prior to the start of each test period. The 30-day test will not be considered successful until all data base points and logic functions are tested and verified to be correct.

H. The SAT test is considered successful if the total availability of the system is greater than 99.5 percent. The SAT test shall be restarted or repeated in its entirety if availability if less than 99.5 percent. Availability shall be defined as:

I. Availability in percent = 100 * [(Total Testing Time-Down Time) / Total Testing Time]

J. Down times due to power outages or other factors outside the normal protection devices or back-up power supplies provided shall not contribute to the availability test times above.

K. A failure is the inability of a component to perform its function regardless of the cause or severity of the failure.

L. Failures may range in severity from loss of a single keyboard contact, to inoperability of a workstation or print device, to complete inoperability.

M. Failures may be caused by hardware or software faults. Software faults will be charged against the appropriate hardware component.

N. Failures may be continuous or intermittent. An intermittent failure is a failure that occurs and then disappears before corrective maintenance can be completed. Examples of intermittent failures include, but are not limited to, the following: 1. Communication errors caused by defective master station equipment. 2. “Sticky” keyboard contacts. 3. Peripheral device errors. 4. Operating system errors.

O. Downtime is the period of time between notification that a failure has occurred and notification that repair has been completed. 1. For intermittent failures, downtime is the accumulation of the greater of the actual

duration of each intermittent failure or 15 minutes per occurrence. This accumulation starts at failure modification and ends at repair complete notification, subject to verification of the repair by the Owner.

2. Verify the end of downtime by testing repairs.

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P. A component is any equipment that is consistent in nature and function as those specified. Component examples include, but are not limited to, operation workstations, PLCs, disk drives, the master station computers, printers, data network, modems and similar hardware.

Q. Availability is the fraction of operating time a component is capable of performing its intended function.

R. A PLC unit is considered down and downtime will be recorded upon occurrence of any of the following: 1. Errors in data translation. 2. Loss of numerical data.

S. Throughout the duration of the 30-day SAT, no software or hardware modifications shall be made to the system without prior approval from the Owner and Engineer.

T. Upon successful completion of the 30-day site acceptance test and subsequent review and approval of complete system final documentation, the system shall be considered substantially complete and the one year warranty period shall commence.

U. Certification of Installation: Following successful completion of the 30-day test, the GC shall issue a Certification of Installation. Certification shall be on GC corporate letterhead and signed by an officer of the firm. Certification shall state that the process control system has been completed in conformance with plans and specifications. Certification shall be submitted to the Engineer as specified herein.

END OF SECTION

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I&C – TRAINING Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13303 I&C - TRAINING.DOC

SECTION 13303 INSTRUMENTATION AND CONTROLS - TRAINING

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Provide all equipment, materials, incidentals and labor, necessary to perform and coordinate the overall system training for the Process Control System.

B. The General Contractor (GC) shall supervise the requirements of this section and the Application Services Provider (ASP) shall perform all training.

C. As part of these services, the GC shall include, for those equipment items not manufactured by him, the services of an authorized manufacturer’s representative to provide training as set forth within this section and related sections of the specifications.

1.2 RELATED WORK

A. Refer to Section 13300 Instrumentation and Controls-General Provisions

1.3 SUBMITTALS

A. The ASP shall prepare and submit a complete overall Process Control System training plan.

B. The training plan shall include: 1. Definitions, objectives, and target audience of each course 2. Schedule of training courses included proposed dates, duration and locations of each

class. 3. A complete copy of all proposed handouts and training materials. Training information

shall be bound and logically arranged with all materials reduced to a maximum size of 11-inch by 17-inch, then folded to 8.5-inch by 11-inch for inclusion into the binder.

PART 2 - PRODUCTS – NOT USED

PART 3 - EXECUTION

3.1 TRAINING

A. General: 1. The cost of training programs for the Owner’s personnel shall be included in the

Contract price. The training and instruction shall be directly related to the system being supplied. The training program shall represent a comprehensive program covering all aspects of the operation and maintenance of the system.

2. All onsite instructors must be intimately familiar with the operation and control of the Owner’s facilities.

3. All Technicians, Operators, Engineers, and Managers of the facility shall require training on the Process Control System (PCS). The training courses shall address operation, maintenance, and troubleshooting of the system provided. The courses shall be designed specifically for the type of personnel attending, such as operators, engineers, etc.

4. All training schedules shall be coordinated with and at the convenience of the Owner. Shift training may be required to correspond to the Owner’s working schedule.

5. Provide detailed training manuals to supplement the training courses. The manuals shall include specific details of equipment supplied and operations specific to the

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project. The manuals shall be provided for each student. Provide electronic copy of each training manual in PDF format for Owner’s future use.

6. The trainer shall make use of teaching aids, manuals, slide/video presentations, etc. After the training services, all training materials shall be delivered to Owner.

7. The Owner reserves the right to videotape all training sessions. All training tapes shall become the sole property of the Owner.

8. All training shall be performed at the Flower Mound WWTP site.

B. The training courses listed as follows shall, as a minimum, be provided:

Course Description Course

Duration (hours)

Number of Trainees Furnished by:

Integrated Control System 8 4 ASP PLC Hardware/Software 4 4 ASP Field Instruments 4 4 ASP Panel Instruments 2 4 ASP Operator (Pre-Startup) 4 4 ASP Operator (Post-Startup) 4 4 ASP

1. Integrated Control System Training:

a. Human Machine Interface (HMI): 1) Provide training for the Owner’s personnel in the functionality,

maintenance, and troubleshooting, of the specific installed equipment for this project. The training shall be held before the Functional Demonstration Test (FDT), but not more than two months before.

2) Training personnel shall be intimately familiar with the new control system equipment, its manipulation, and configuration. Training personnel shall command knowledge of system debugging, program modification, troubleshooting, maintenance procedure, system operation, and programming, and shall be capable of transferring this knowledge in an orderly fashion to technically oriented personnel.

3) Training and instruction shall be specific to the specific systems that is being supplied.

4) Training shall consist of classroom and hands-on instruction utilizing the Owner’s system.

5) Detailed training shall be provided on the actual configuration and implementation for this contract. Training shall cover all aspects of the system that will allow the Owner’s personnel to maintain, modify, troubleshoot, and develop future additions/deletions to the system. The training shall cover the following subjects, as a minimum: a) System overview a) System hardware components and specific equipment arrangements b) System startup, shutdown, load, backup, and historical

archival/retrieval procedures c) Specific application configuration covering the overall design and

implementation of the applications provided under this contract. The intent is to make the student fully knowledgeable in all aspects of the system provided.

d) Periodic maintenance e) Troubleshooting and diagnosis f) Network configuration, communications, and operation g) SCADA system hardware operating system operation and

maintenance

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h) System backups and reload procedures i) Ethernet/IP and TCP/IP addressing procedures

b. Programmable Logic Controller (PLC) Hardware and Software: 1) Provide training for the Owner’s personnel in the operation, maintenance,

troubleshooting, etc. with the PLC hardware and software system. The training shall be held before the FDT, but not more than two months before.

2) Training and instruction shall be specific to the system that is being supplied.

3) Training shall consist of classroom and hands-on instruction utilizing the Owner’s system.

4) Detailed training shall be provided on the actual configuration and implementation for this contract. Training shall cover all aspects of the system that will allow the Owner’s personnel to maintain, modify, troubleshoot, and develop future additions/deletions to the system. The training shall cover the following subjects, as a minimum: a) PLC System overview b) PLC System hardware components and specific equipment

arrangements c) PLC System startup, shut down, load, backup, and historical

archival/retrieval procedures d) Specific application configuration covering the overall design and

implementation of the applications provided under this contract. The intent is to make the student fully knowledgeable in all aspects of the system provided.

e) Periodic maintenance f) Troubleshooting and diagnosis down to the I/O card level. g) Network configuration, communications, and operation.

C. Field Training: 1. Field Instruments:

a. Provide a minimum of one 8-hour hardware training and instruction on the maintenance of the field instrumentation. This training shall be conducted before the Functional Demonstration Test, but no more than one (1) month before and at a time suitable to the Owner. This training shall take place at the Owner’s facility. As a minimum the following shall be included: 1) Training in standard hardware maintenance for the instruments provided 2) Specific training for the actual instrumentation configuration to provide a

detailed understanding of how the equipment and components are arranged, connected, and set up for this contract

3) Test, adjustment, and calibration procedures 4) Troubleshooting and diagnosis 5) Periodic maintenance

2. Panel Instruments: a. Provide a minimum of one 8-hour hardware training and instruction in the

maintenance of the panel instrumentation. Training should be conducted before the Functional Demonstration Test, but not more than one (1) month before and at a time suitable to the Owner. This training shall be provided at the Owner’s facility and at a minimum the following shall be included: 1) Training in standard hardware maintenance for the instruments provided 2) Specific training for the actual instrumentation configuration to provide a

detailed understanding of how the equipment and components are arranged, connected, and configured for this contract

3) Test, adjustment, and calibration procedures 4) Troubleshooting and diagnosis 5) Periodic maintenance

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3. Panel Functions: a. Provide a minimum of two 2-hour training sessions on the detailed operation of

the touch screen panel. This training shall be conducted within two (2) days of the completion of the Functional Demonstration Test at times suitable to the Owner. This training shall be provided at the Owner’s facility and at a minimum, the following shall be included: 1) Specific training for the actual instrumentation configuration to provide a

detailed understanding of how the equipment and components are arranged, connected, and set up for this contract.

END OF SECTION

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I&C – APPLICATION SERVICES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13305 I&C - APPLICATION SERVICES.DOC

SECTION 13305 INSTRUMENTATION AND CONTROLS - APPLICATION SERVICES

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The General Contractor (GC) shall procure the services of an Application Service provider (ASP), as a second-tier subcontractor (to the General Contractor), who shall furnish the Programmable Logic Controller (PLC) (PLC-MSB) programming, Human Machine Interface (HMI) graphics development, HMI software configuration, HMI database development, testing of PLC-MSB logic, testing the monitoring signals of the new Belt Filter Press Control Panels (PLC-BFP1 and PLC-BFP2), testing the monitoring signals of the new Lime Stabilization System Control Panel (PLC-SSCP), and startup/training activities associated with the programmed portions to be furnished by the ASP and other vendor supplied equipment.

B. This specification is a performance-based document and it defines the minimum requirements for the ASP. Basic information is provided regarding the ASP scope of work to assist the GC in determining their role in providing support services to the ASP.

C. It shall be the responsibility of the GC and ASP to obtain and provide any and all information required from other Divisions, as listed in the related work below, for the ASP to complete the work under this Section.

D. The GC, in conjunction with the ASP and other vendors, shall schedule all testing procedures for the PLC-MSB, PLC-BFP1, PLC-BFP2, PLC-SSCP and HMI. These testing procedures shall be incorporated within the ASPs testing plan.

E. The Owner shall provide the ASP an electronic copy of the current PLC-MSB programs that require modification. In addition, the Owner shall provide the ASP an electronic copy of the current HMI database and graphics that require modification. During the time that the ASP has these programs, any change made by anyone else to PLC-MSB, may be lost or overwritten if not coordinate with the ASP.

F. The ASP shall provide all applications programming and services required to achieve a fully integrated and operational control system and coordinated with the control system for proper operation with related equipment and materials furnished by other suppliers under other Sections of these specifications and with related existing equipment.

G. To facilitate the Owner’s future operation and maintenance, PLC programming and SCADA HMI operator interface development shall utilize standards as agreed upon by the Owner and Engineer.

H. Auxiliary and accessory programming structures necessary for proper system operation and performance shall be included whether or not they are shown on the contract drawings. 1. All equipment shall be controlled in full conformity with the contract drawings, process

control descriptions, specifications, engineering data, instructions, and recommendations of the equipment manufacturer.

2. All work shall be coordinated with plant operating personnel to minimize impacts on daily operation. Delays caused for any reason shall be noted and formally submitted to the Engineer and the Owner in the form of a letter.

I. The ASP shall provide all process controller programming and Human Machine Interface (HMI) configuration including development of control programs, database configuration, graphic screens, communication links, historical archiving, as specified herein. The ASP shall perform the following generalized functions: 1. Reconfiguration/modification of the existing HMI System Software and drivers as

necessary.

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2. Reconfiguration/modification of the existing SCADA Historian Software to include the facilities being executed under this project.

3. Reconfiguration/modification of system reports to reflect all of the facility’s processes being executed under this project.

4. Provide for and test Ethernet and Fiber Optic communications and functionality between all newly connected devices (such as PLCs) and the HMI software package as depicted on the system architecture drawings.

5. Configure and test data collection and interactivity between all software packages and PCs in order to provide a comprehensive working system of data collection, storage and reporting.

6. Provide HMI graphics and configuration, PLC programming, historical logging configuration, historical reports, coordination, testing, and startup services as needed to integrate the new packaged equipment systems into the overall plant Control System. Several of these systems are “stand-alone” and will be programmed, tested, commissioned, and warranted by the suppliers themselves. The ASP shall be responsible for coordinating the sharing of monitoring, control, historical, and alarm data with the suppliers over the Ethernet Global Data interface of each system as appropriate for the individual systems. The ASP is not responsible for the operation of the individual systems. The ASP is responsible to monitor and provide supervisory commands or set point changes to the packaged systems, and collect information for historical logging and reporting.

7. Perform real-time process control, including proportional integral derivative control action, sequencing, process calculations, etc.

8. Collect and store accurate, reliable operating information for present and future uses. 9. Assist remote site operating personnel by noting and communicating off normal

operating conditions and equipment failures. 10. Accumulate and store equipment running times for use in preventative maintenance. 11. Provide color graphic displays and reports for use by the system operating and

supervisory personnel. 12. Provide trending for all new analog values. 13. All process control functions including PID, calculations, sequencing, timing, etc., shall

be done in the PLC. The HMI software shall perform the real-time database, report generation, graphic screens, program development, set point modification, data archiving, etc.

14. The system shall allow the operator to manually control (by keyboard entry and mouse type pointing device) the status of pumps, valves, etc. (i.e., on off, open close, set point value, etc.) when viewing the appropriate graphic screen on the HMI.

1.2 RELATED WORK

A. Section 13300 I&C - General Provisions

B. Section 13302 I&C - Testing

C. Section 13303 I&C - Training

D. Section 13400 I&C - Process Control Descriptions

1.3 SUBMITTALS

A. Prior to the beginning the submittal process, the ASP shall hold specific workshops, in which the Engineer and/or Owner may observe the displays and control strategies prior to submittal of the database, trends, graphics, reports, and control strategies.

B. Submit all required submittals in accordance with Section 13300, Submittals. The submittals listed below shall be provided as a minimum.

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List No. Submittal Description Submittal Number Section(s) with

Requirements

1 Operator Interface 13305-001 13300, 13400

2 Process Control Strategy 13305-002 13300, 13400

3 Historical Data Management and Reports 13305-003 13300, 13400

4 Software Maintenance Documentation 13305-004 13300, 13400

5 Operations and Maintenance Manuals 13305-005 13300, 13400

C. Operator Interface Submittal 1. Submit all proposed graphic displays, examples of each type of pop-up (faceplate)

displays, and examples of trends. 2. Submitted graphic displays and trends shall be no less than 8.5-inches by 11-inches

and in full color. 3. Quantity of graphic displays to be provided shall be as required to depict all monitoring

and control requirements defined herein and in the contract documents. All processes and equipment shown on the P&ID drawings shall be shown in a similar manner. The graphic displays shall represent all process flow paths and all associated equipment units, pumps, meters, valves, gates, feed systems and auxiliary systems. As a minimum, the following graphic displays and types shall be provided: a. Plant Overview Display b. Index Displays c. Process Overview Displays d. Unit Process Displays e. Process Detail Displays f. Alarm Summary Display g. System Diagnostic Displays h. Tabular Displays i. Control Strategy Setup Displays j. Equipment Control Pop-up Displays k. Trend Displays

4. Pre-defined trend displays shall be developed for easy recall using index display or standard display recall buttons. Pre-defined trends shall be developed for all analog inputs. Grouping of analog inputs shall be as defined by the Engineer/Owner. A maximum of 8 points shall be assigned to a trend. A prominent "back" button shall be on every display to switch the graph back to the previously viewed display.

D. Process Control Strategy Submittal 1. This submittal shall present all control schemes to be developed and shall include the

following as a minimum: a. A brief description of the scope of the control function b. Listing of all scanned inputs to the control function c. A short narrative of the control strategy d. Any assumptions made in developing the program. e. I/O database listing showing all inputs and outputs (i.e., AI, DI, AO, DO)

associated with the control function. f. Cross reference list of all I/O showing to which I/O modules or software modules

they are linked.

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g. Listing of all operator inputs/outputs to and from the control function. A description of the operation of any panels shall be described as it relates to the control function.

h. All failure contingencies shall be described in detail. 2. All applications programs shall be developed in a structured manner and shall follow

an intuitive arrangement so that an instrumentation technician with basic programming knowledge will be able to understand. Programs shall utilize standard program templates or subroutines for repetitive logic such as equipment control, flow total calculations, equipment runtime calculations.

3. All applications programs shall be submitted in 8.5 -inch x 11-inch format. All programs shall be fully annotated and all rungs, contacts, coils and listings labeled.

4. This submittal shall also include copies of the PLC I/O configuration tables, I/O reference usage table, complete cross reference to specific rung used of all inputs, outputs, internal coils, data registers, and special purpose coils. In addition, any special switch settings or hardware configuration requirements such as communications port configurations shall be described in detail and submitted.

E. Historical Data Management and Reports Submittal 1. Conduct a Historical Data Management and Reports Workshop to review the proposed

historical data management and reporting system to be developed and solicit Engineer’s and Owner’s input for the development of the data entry templates, report formats and layouts, and user interface displays for accessing and generating reports.

2. This submittal shall define all aspects of the historical data management system and report generation and shall include as a minimum the following: a. A complete listing of all signals to be collected and stored. This listing shall

include data sampling rate and duration for which the data will be immediately accessible. All process analogs and all run indications of all primary process equipment motors shall be sampled and stored in the historical data management system.

b. Data reduction methods, rates and duration data will be immediately accessible. c. Storage space requirements and supporting calculations d. Description of historical database design, including table definitions, procedures

used, and queries used. Method of accumulating and displaying run times and flow totals shall be described.

e. A complete list of all reports to be developed f. Description of methodology for entering manual data g. Procedures for recall, generation and printing of reports h. Printout of each report to be provided i. Description of methodology for restoring data collected locally during times that

the historical data management system is not available. j. Description of selecting only the active real-time data source for systems that are

utilizing redundant data acquisition nodes k. List of data source interfaces to be supplied with the system (for example, OPC,

file collection, historian-historian collector, HMI applications, etc.) 3. Quantity and format of reports shall be determined at the workshop and as a minimum

shall include Daily Operations Reports, Normalized Membrane Operational Data, Daily Equipment Maintenance Reports, Status/Alarm Reports, Chemical Usage Reports, Electrical power Usage Reports, Monthly Operating Reports and Quarterly Injection Reports.

F. Software Maintenance Documentation Submittal 1. Application/Custom Software Manuals - All software maintenance information not

included in the system supplier's standard manuals. Each custom program developed specifically for the system shall include the following information as a minimum: a. Table of Contents b. Overview of the program

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c. Narrative describing specifically how the program works. All calculations, references to process I/O points and operator inputs should be mentioned and cross referenced to the logic diagrams or code.

d. Flowcharts or system logic diagrams in Boolean format shall be provided to clarify the narrative description.

e. A List of Variables used by the program including the function of each. A cross reference to the Software Functional Design Documentation shall be provided where appropriate.

2. Software Listings and Databases- Submit copies of well annotated as-built program listings of all software provided shall be furnished for all software items. Listings shall reflect the as-built condition of the logic development submitted as part of the shop drawing review process. Listings shall include, but not be limited to, the following: a. All listings associated with the system generation and software configuration

(e.g., system parameterization tables, build maps, disk maps, etc.). Submittals shall be included for process controllers, HMI application software, LOP application software, database applications, and all other equipment where specific programs or scripts were developed for this project.

b. Listings of all data bases configured for and associated with the system. c. Listing of all custom or modified software developed specifically for the system.

Listings shall reflect any changes made after the factory acceptance test. 3. Machine Readable Documentation - the supplier shall provide two sets of as built

documentation on CD-ROMs in machine readable format for all programs developed under this Contract. The machine readable documentation shall be 100 percent compatible with the Software Listings previous defined and include all documentation files including logic and annotation files. Any changes made during or after factory acceptance test shall be incorporated.

G. Operations and Maintenance Manuals Submittal 1. The ASP shall provide Operator's Manuals for the system operators. These manuals

shall be separately bound and shall contain all information necessary for Operations Staff to operate the system. The manuals shall be written in non-technical terms and shall be organized for quick access to each detailed description of the Operator's procedure. Manuals shall contain, but not be limited to, the following information: a. A simple overview of the entire system indicating the function and purpose of

each piece of equipment b. A detailed description of the operation of the HMI and Local Operator Panels

including all appropriate displays c. A detailed operational description of all hardwired panels d. Step-by-step procedures for starting up or shutting down an individual component e. Step-by-step procedures for starting up and shutting down the entire system f. A comprehensive description of the operation and control of each plant process.

All operator actions to these processes and the associated reaction described. g. Operational description for operating HMI computer equipment and peripherals

including printers, CD-ROMs, removable bulk storage devices, UPS, etc. Description shall include procedures for typical maintenance and troubleshooting tasks.

h. A listing of all data base point names with their respective English language point descriptions and HMI graphic screen cross reference where the points can be found

i. A complete glossary of terms. j. Complete, step-by-step procedures for performing complete system or selected

file backup and restoration. k. Submit annotated chart recorder traces or computer system trend screen

printouts showing tuned control loop response to plus and minus 40 percent of full span step changes of loop set point. For cascade loops, submit charts

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showing response of the secondary loop with secondary set point on manual and also response of the entire cascade control loop in automatic mode.

l. Submitted charts shall be created with time and amplitude settings to allow verification of loop stability and performance. Calibrate the chart to allow clear traces for the full span of the process including any overshoot. Charts that exhibit clipping shall not be acceptable. Each chart shall be annotated with project name, system loop number, chart function (set point response verification, process variable response verification, or PID parameter development), PID loop parameter settings, date, time, and name of the testing/tuning technician. A separate chart shall be submitted for each tuned loop. Each chart shall be neatly mounted or copied on 8.5-inch by 11-inch or 11-inch by 17-inch sheets suitable for incorporation in the final documentation binders.

2. Include software O&M materials as part of 13300 “Final System Documentation” This required information is in addition to any requirements of Section 13300.

3. Provide operations and maintenance manuals in accordance with requirements of Sections 13300.

4. Prior to final acceptance of the system, operating and maintenance manuals covering all operations and maintenance procedures for the applications software and system configuration shall be furnished.

5. All software applications, programs and configuration files shall be provided on electronic media disks independent of computer hard disk files.

6. The manuals shall contain operating and maintenance data written specifically for this project, but may include standard and modified standard documentation. Modifications to existing hardware or software manuals shall be made on the respective pages or inserted adjacent to the modified pages. All standard documentation furnished shall have all portions that apply clearly indicated. All portions that do not apply shall be lined out.

7. The manuals shall contain all illustrations, detailed drawings and instructions necessary for installing, operating and maintaining the applications software. All illustrations shall be numbered for identification. All information contained therein shall apply specifically to the application software furnished and shall only include instructions that are applicable. All such illustrations shall be incorporated within the printing of the page to form a durable and permanent reference book.

8. If the ASP transmits any documentation or other technical information that is considered proprietary, such information shall be designated. Documentation or technical information that is designated, as being proprietary will be used only for the design, construction, operation, or maintenance of the System and, to the extent permitted by law, will not be published or otherwise disclosed.

9. Final documentation shall include the results of all PID controller loop tuning procedures per the requirements of Part 3 of this specification. Submit tuning documentation for all PID loops included in this Contract including all identical loops in parallel process trains.

10. As a minimum, the following information shall be provided in the manuals: a. A comprehensive index b. All documentation from previous submittals updated to reflect the as built system c. Detailed service, maintenance and operation instructions for each item supplied,

including procedures for backing up files and archiving historical data. d. Recommended archiving schedule for historical data

11. List of personnel to be contacted for warranty and emergency services, including name, address, telephone number, pager or cell phone number, fax number, and email address.


A. Refer to section 13300

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1.5 WARRANTY


PART 2 - PRODUCTS (NOT USED)

PART 3 - EXECUTION

3.1 COORDINATION MEETINGS AND WORKSHOPS

A. Refer to Section 13300 for requirements pertaining to ASP attendance at GC/ASP Project Coordination Meetings.

B. For the purpose of the ASP coordinating the work specified herein, the ASP shall schedule and administer the following workshops: 1. Preliminary Graphics Workshop 2. Historical Data Management and Reports Workshop

C. The ASP shall make arrangements for the workshops and prepare and send a proposed agenda to all participants at least one (1) week before workshops are held. The ASP shall be responsible for promptly preparing and distributing minutes to all attendees.

D. The workshops shall be held at the General Contractor’s field office at the project site or as designated by the Owner and shall include, at a minimum, attendance by the Owner, Engineer, General Contractor’s project engineer, and ASP.

E. The first workshop shall be held in advance of the first ASP shop drawing submittal. The first workshop may run concurrent with a GS/ASP coordination meeting if desired and timed to meet all other contract requirements.

F. The ASP shall schedule and administer the Preliminary Graphics Workshop. During the Preliminary Graphics Workshop, the ASP shall present templates, samples from other projects, an initial screen list, and samples of system navigation tools to the Owner for consideration. The Owner will make comments on the system for incorporation by the ASP prior to the Operator Interface Submittal. The ASP shall bring a working system to allow for a live demonstration of the various software tools.

G. Thee ASP shall schedule and administer a Historical Data Management and Reports Workshop to discuss and solicit Owners input on requirements for storage and management of historical data and format of reports.

END OF SECTION

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I&C – FLOW DEVICES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13310 I&C - FLOW DEVICES.DOC

SECTION 13310 INSTRUMENTATION AND CONTROLS - FLOW DEVICES

PART 1 - GENERAL

1.1 SUMMARY

A. This section covers the furnishing, installation, and services for the field-mounted Flow instruments, major systems, panels, and subassemblies as detailed on the drawings.

B. Flow equipment, specified in other Divisions, shall be manufactured in accordance with this Section and submitted as a part of the equipment specified in other Divisions.

1.2 SUBMITTALS


B. Submit catalog data for all items supplied from this specification Section as applicable. Submittal shall include catalog data, functions, ratings, inputs, outputs, displays, etc., sufficient to confirm that the meter or relay provides every specified requirement. Any options or exceptions shall be clearly indicated.

C. Submittals for equipment specified herein, for other Sections or Divisions, shall be made as a part of equipment submittals furnished under other Sections or Divisions.

1.3 REFERENCE STANDARDS

A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. IEC 79-10 Intrinsically Safe Circuits 2. 913 Electrical Instruments in Hazardous Atmospheres

B. All instruments, relays and associated equipment shall comply with the requirements of the National Electric Code and Underwriters Laboratories (UL) where applicable.

C. Each specified device shall also conform to the standards and codes listed in the individual device paragraphs.


A. The manufacturer of this equipment shall have produced similar instrumentation equipment for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

B. Equipment submitted shall fit within the space or location shown on the Drawings. Equipment which does not fit within the space or location is not acceptable.

C. For the equipment specified herein, the manufacturer shall be ISO 9001 2000 certified.

1.5 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for two (2) years from date of acceptance of the equipment containing the items specified in this Section. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Contractor at no expense to the Owner.

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PART 2 - PRODUCTS

2.1 MAGNETIC FLOW METERING INSTRUMENTS

A. Magnetic Flow meter 1. Flow Element

a. Type: Pulsed DC electromagnetic induction type and shall provide a signal which is linear to the liquid flow rate.

b. Function/Performance: 1) Power requirements: Match to converter/ transmitter. 2) Accuracy: Plus or minus 0.5 percent of actual rate of full scale (including

converter/transmitter). 3) Temperature rating: Suitable for process liquid temperature up to 70

degrees C and an ambient of 65 degrees C. 4) RFI protection: Provide RFI protection. 5) Pressure rating: 240 PSI if 150 lb flanges are used, 700 PSI if 300 lb

flanges are used. 6) Additional: Meter shall be capable of running empty indefinitely without

damage to any component. c. Physical:

1) Metering Tube: Carbon steel with 304 Stainless interior unless otherwise indicated.

2) Flanges: Match piping AWWA rating of the pipe. Minimum AWWA 150# Flange.

3) Liner: Polyurethane or EDPM unless noted otherwise. Liner shall be suitable for Thickened Sludge material.

4) Electrodes: 316 stainless steel, bullet nosed or elliptical self cleaning type unless otherwise noted.

5) Housing: Meters in below grade vaults, basements, etc., shall be designed for accidental submergence in 30 feet of water for 24 hours. Where hazardous areas are indicated on the contract drawings, the equipment shall be rated for that area.

6) Painting: All external surfaces shall be painted with a chemical and corrosion resistant epoxy finish.

d. Accessories/Options Required: 1) Factory calibration: All meters shall be factory calibrated. A copy of the

report shall be in the O&M manual. 2) Grounding: Meter shall be grounded per the manufacturer’s

recommendation. Provide ground ring, ground wires, and gaskets, etc., or as otherwise noted. All materials shall be suitable for liquid being measured.

e. Approved Manufacturers are: 1) Siemens. 2) Endress & Hauser. 3) Toshiba. 4) Foxboro. 5) Approved Equal.

2. Flow Converter/Transmitter a. Type: Match to flow element. b. Functional/Performance:

1) Power requirements: 120VAC plus or minus 10 percent. 2) Accuracy: As defined for flow element. 3) Temperature: minus 25 degrees C to plus 65 degrees C. 4) Output: Isolated 4-20 mA into 0-1000 ohms. 5) Provide the Flow Transmitter with HART Communication.

c. Physical: NEMA 4X wall mount.

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d. Accessories/Options Required: 1) Cable: Provide signal cable between magmeter and signal converter. 2) Indicator: Provide local indicator with scale engraved 0-100 percent which

indicates actual converter output signal. 3) Totalizer: Provide the Instrument with a seven digit, non-reset totalizer on

the face of the enclosure, and a scalable pulse output to drive the totalizer. The totalizer multiplier shall be a power of 10.

4) Zero Return Unit: Provide the Instrument with a zero return unit. The unit shall be powered from the converter/transmitter and may be mounted in a separate NEMA 4X enclosure; the device shall drive the magmeter output to 4 mA DC on no flow conditions.

5) Provide a Verificator device along with magnetic flow meter. This shall be the same manufacture of the magnetic flow meter. Also provide half day training for the Owner maintenance team and written procedure for using the Verificator. This training in addition to that defined elsewhere.

e. Manufacturer(s): To be supplied with flow element.


A Factory calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the NIST. 1. Submit calibration data sheets to the ENGINEER at least 30 days before shipment of

the instruments to the project site.

PART 3 - EXECUTION

3.1 INSTALLER’S QUALIFICATIONS

A. Installer shall be specialized in installing this type of equipment with minimum 5 years documented experience.

3.2 EXAMINATION

A. Examine installation area to assure there is enough clearance to install the equipment.

B. Verify that the equipment is ready to install.

C. Verify field measurements are as instructed by the manufacturer.

3.3 INSTALLATION

A. The Contractor shall install all equipment per the manufacturer's recommendations and Contract Drawings.

B. All process connections shall be 316 stainless steel tubing, 3/8” minimum, unless otherwise shown on the Drawings. Fittings shall be of the compression type, 316 stainless steel.

C. All conduit entries into the instruments shall use hubs of watertight, threaded aluminum, insulated throat, stainless steel grounding screw, as manufactured by T&B H150GRA Series, or Equal.

D. Install stainless steel instrument labels with instrument ID, secured with safety wire.

3.4 RACEWAY SEALING

A. Where raceways enter terminal boxes, junction boxes, or instrumentation equipment, all entrances shall be sealed with 3M 1000NS Watertight Sealant, or Approved Equal.

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A. Inspect installed equipment for anchoring, alignment, grounding and physical damage.

B. Check tightness of all accessible electrical connections. Minimum acceptable values shall be specified in the manufacturer's instructions.

3.6 FIELD ADJUSTING

A. Adjust all equipment for proper range and field conditions, as described in the manufacturer's instructions.

B. Any field adjustments, required for proper system operation, shall be included in the Final O&M.

3.7 FIELD TESTING

A. Perform all electrical field tests recommended by the manufacturer.

B. Test each interlock system for proper functioning.

C. Test all control logic for proper operation.

3.8 CLEANING

A. Remove all rubbish and debris from inside and around the equipment. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.

3.9 EQUIPMENT PROTECTION AND RESTORATION

A. Touch-up and restore damaged surfaces to factory finish, as approved by the manufacturer. If the damaged surface cannot be returned to factory specification, the surface shall be replaced.

3.10 MANUFACTURER’S CERTIFICATION

A. A qualified factory-trained and certified representative shall certify in writing that the equipment has been installed, adjusted, including all settings as defined in the Contract Documents.

B. The Contractor shall provide three (3) copies of the representative’s certification.

END OF SECTION

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I&C – LEVEL DEVICES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13312 I&C - LEVEL DEVICES.DOC

SECTION 13312 INSTRUMENTATION AND CONTROLS - LEVEL DEVICES

PART 1 - GENERAL

1.1 SUMMARY

A. This section covers the furnishing, installation, and services for the field-mounted Level instruments and analyzers, major systems, panels, and subassemblies as detailed on the drawings.

B. Level equipment, specified in other Divisions, shall be manufactured in accordance with this Section and submitted as a part of the equipment specified in other Divisions.

1.2 SUBMITTALS

A. Refer to Section 13300

B. Submit catalog data for all items supplied from this specification Section as applicable. Submittal shall include catalog data, functions, ratings, inputs, outputs, displays, etc., sufficient to confirm that the meter or relay provides every specified requirement. Any options or exceptions shall be clearly indicated.

C. Submittals for equipment specified herein, for other Sections or Divisions, shall be made as a part of equipment submittals furnished under other Sections or Divisions.


A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. ANSI B40.1 Pressure Gauges 2. ASME PTC 19.2 Pressure Measurement 3. ANSI B88.1 Pressure Transducers Calibration 4. ISA S37.6Strain Gage Transducers Potentiometric 5. ISA S37.3 5 Vacuum Gauges 6. Calibration AVS 6.2, 6.4, 6.5 Hazardous Areas 7. IEC 79-10 Intrinsically Safe Circuits 8. 913 Electrical Instruments in Hazardous Atmospheres







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1.5 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for two (2) years from date of acceptance of the equipment containing the items specified in this Section. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Contractor at no expense to the Owner.

PART 2 - PRODUCTS

2.1 LEVEL INSTRUMENTS

A. Weighted Float Type Level Switches 1. Type: The switch assembly shall be weighted and suspended on its own cable. 2. Function/Performance:

a. Temperature Rating: 0-50 degrees C. b. Contact Rating: Up to 250V AC/DC, and 8 amps AC, 5 amps DC. c. Contact Arrangement: Form C contact which is field selectable normally open or

closed. 3. Physical:

a. Contact: Sealed mercury free switch housed in a chemical-resistant polypropylene or depending on the application.

b. Flexible Support Cable: Synthetic three wire cable, minimum 19 AWG wire. c. Specific Gravity: Match to fluid being measured.

4. Options/Accessories Required: a. Provide flexible support cable of sufficient length to ensure no splice or

connection is required in the wetwell. b. Provide junction box outside the wetwell for connection of cable. c. Provide stainless steel supports/mounting accessories as required.

5. Manufacturers: a. Flygt Model EMH-10 b. Contegra FS-90 c. Approved Equal.

B. Float Switch - Fixed Mount 1. Type:

a. Ball float switch. 2. Function/Performance:

a. Differential: Less than one inch. b. Switch Rating: 20 amps at 120VAC, 10 amps at 240VAC.

3. Physical: a. Float: 316 stainless steel, 5-1/2-in diameter. b. Switch: Totally encapsulated mercury free switch. c. Cable: Heavy duty, PVC jacketed integral to float.

4. Options/Accessories Required: a. Provide stainless steel hardware. b. Lead wire shall be a waterproof cable of sufficient length so that no splice or

junction box is required in the wet well. c. Provide cast-aluminum weatherproof junction box outside the wet well with

terminals for all floats and tapped as required for conduit connections. 5. Manufacturer(s):

a. Contegra FS-90 b. Approved Equal.

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PART 3 - EXECUTION



3.2 EXAMINATION




3.3 INSTALLATION



C. All conduit entries into the instruments shall use hubs of watertight, threaded aluminum, insulated throat, stainless steel grounding screw, as manufactured by T&B H150GRA Series, or equal.


3.4 RACEWAY SEALING

A. Where raceways enter terminal boxes, junction boxes, or instrumentation equipment, all entrances shall be sealed with 3M 1000NS Watertight Sealant, or approved equal.




3.6 FIELD ADJUSTING



3.7 FIELD TESTING




3.8 CLEANING


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B. The Contractor shall provide three (3) copies of the representative’s certification.

END OF SECTION

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I&C – PRESSURE DEVICES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13314 I&C - PRESSURE DEVICES.DOC

SECTION 13314 INSTRUMENTATION AND CONTROLS - PRESSURE DEVICES

PART 1 - GENERAL

1.1 SUMMARY

A. Furnish, install and test all pressure measurement, pressure control devices and appurtenances, as shown on the Drawings, specified in the Related Work Sections and Divisions, and as specified herein.

B. Pressure equipment, specified in other Divisions, shall be manufactured in accordance with this Section, and submitted as a part of the equipment specified in other Divisions.

1.2 SUBMITTALS

A. Submit catalog data for all items supplied from this specification Section as applicable. Submittal shall include catalog data, functions, ratings, inputs, outputs, displays, etc., sufficient to confirm that the meter or relay provides every specified requirement. Any options or exceptions shall be clearly indicated.

B. Submittals for equipment specified herein, for other Sections or Divisions, shall be made as a part of equipment submittals furnished under other Sections or Divisions.


A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. ANSI B40.1 Pressure Gauges 2. ASME PTC 19.2 Pressure Measurement 3. ANSI B88.1 Pressure Transducers Calibration 4. ISA S37.6Strain Gage Transducers Potentiometric 5. ISA S37.3 5 Vacuum Gauges 6. Calibration AVS 6.2, 6.4, 6.5 Hazardous Areas 7. IEC 79-10 Intrinsically Safe Circuits 8. IEC 79-3 9. 913 Electrical Instruments in Hazardous Atmospheres 10. ISA RP12.1, 4, 6, 10, 11 Weighing Scales 11. ASME PTC 19.5.1







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1.5 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for TWO (2) years from date of acceptance of the equipment containing the items specified in this Section. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the General Contractor at no expense to the Owner.

PART 2 - PRODUCTS

2.1 DIFFERENTIAL PRESSURE TRANSMITTER

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Endress and Hauser 2. Siemens 3. Rosemount 4. Approved Equal

B. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety.

C. General 1. Provide sufficient lengths of Manufacturer’s specialty cables for installation of power

and signal conductors as provided with each instrument.

D. Type 1. Microprocessor based intelligent type. 2. Diaphragm actuated.

E. Function/Performance: 1. Output: 4-20 mA DC. Output shall be linear for pressure applications. 2. Accuracy: 0.1 percent of span (linear output). 3. Stability: Combined temperature effects shall be less than 0.2 percent of maximum

span per 50 degrees F temperature change. Effect on accuracy due to static pressure changes shall be negligible.

4. RFI Protection: 0.1 percent error between 27 and 500 MHZ at 30 v/m field intensity. 5. Drift: 0.10 percent per six months for 4-20 mA output. 6. Sensor Technology: Digital. 7. Over Range Protection: Provide positive over range protection.

F. Physical 1. Electrical Classification: Intrinsically safe for Class I and Class II, Division 1 locations. 2. Enclosure: NEMA 4X. 3. Sensor Diaphragm Material: Cobalt-Nickel-Chrome alloy or Hastelloy C. 4. Gaskets: Teflon. 5. Sensor Fill Fluid: Shall be suitable for process fluid being measured. When used for

chemical metering service, sensor fill fluid shall be rated specifically for the chemical being measured.

G. Power Requirements: 1. Loop powered, two wire type.

H. Options/Accessories 1. Provide span and zero adjustment at each transmitter. 2. Provide local indication at each transmitter, either analog gauge or LCD readout.

Scale shall be in engineering units.

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3. For each transmitter provide a manifold as specified herein, with the following Modes: a. Normal Mode b. Zeroing Mode c. Isolation Mode d. Calibration Mode e. Blowdown Mode

4. Provide hand held programmer(s) where full setup is not available for the instrument directly.

2.2 DIAPHRAGM SEAL- THREADED

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Red Valve Company, Inc. 2. Ashcroft. 3. Approved equal.


C. General 1. Pressure rating to match pipe rating.

D. Type 1. Thread attached. 2. Welded Metal Diaphragm. 3. Exposed Surfaces - 316 stainless steel.

E. Function/Performance 1. Purpose: To protect instruments or gauges from the process medium. 2. A flexible diaphragm shall separate the process medium from the instrument element.

Space on the instrument side of the diaphragm shall be completely filled with a suitable silicone or instrument oil. The process pressure is transmitted by the liquid filled system to the instrument element.

3. Filling Screw: Include on all units. 4. Pressure Limits: 1,000 psi. 5. Flushing Connection: Include on all units. 6. Capillary tubing as required.

F. Physical 1. Top Housing: Carbon Steel, Cadmium plated. 2. Diaphragm: 316 ELC Stainless Steel. 3. Exposed Surfaces: 316 stainless steel. 4. Bolts, Nuts and Plugs: 18-8 stainless steel or 316 stainless steel. 5. Capillary: 1/4-in stainless steel armor shielded.

G. Power Requirements 1. None

H. Options/Accessories 1. Provide one set of spare gaskets.

2.3 PRESSURE GAUGE

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable. 1. Ashcroft Model 1279 2. Ametek/U.S. Gauge Division 3. Approved Equal

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C. General 1. Pressure ratings shall be equal to or exceed the piping.

D. Type: 1. Bourdon tube actuated pressure gauge.

E. Function/Performance: 1. Accuracy: Plus or minus 1.0 percent of span or better.

F. Physical: 1. Case: Phenolic shock resistant or 316 stainless steel for surface/stem mounting with

a pressure relieving back. The case shall be vented for temperature/atmospheric compensation. Gauge shall be capable of being liquid filled in the field or at the factory.

2. Window: Clear acrylic or shatter proof glass. 3. Bourdon Tube: 316 stainless steel. 4. Connection: ½-in NPT. 5. Gauge size: Minimum 4.0 inches viewable. 6 Pointer travel: Not less than 200 degrees or more than 270 degree arc. 7. Range: As indicated in the instrument device schedule.


H. Options/Accessories 1. Shutoff valve: Each gauge shall have a process shutoff valve which can also be used

as an adjustable pressure snubber. 2. Special scales: The Engineer reserves the right to require special scales and/or

calibration if the manufacturer’s standard is not suitable for the application. 3. Gauges listed as liquid filled in the Instrument Device Schedule shall be liquid filled at

the Manufacturer’s Factory.

2.4 PRESSURE SWITCH

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Static-O-Ring (SOR) 2. United Electric 3. Ashcroft 4. Approved Equal


C. General 1. Pressure ratings shall be equal to or exceed the piping.

D. Type: 1. Diaphragm actuated.

E. Function/Performance: 1. Repeatability: Greater than 1.0 percent of pressure. 2. Setpoint: Field adjustable and set between 30 and 70 percent of the adjustable range. 3. Dead Band: Adjustable 4. Reset: Unit shall be of the automatic reset type unless noted otherwise on the

Instrument Device Schedules.

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5. Over Range Protection: Over range protection to maximum process line pressure. 6. Switch Rating: 250V AC at 10 amps; and 30V DC at 5 amps.

F. Physical: 1. Housing: NEMA 4X. 2. Switching Arrangement: Single pole double throw (SPDT) unless double pole double

throw (DPDT) switches are shown on the instrument device schedule. 3. Wetted Parts: Teflon coated diaphragm, viton seals, stainless steel connection port. 4. Connection Size: ½-in NPT.


H. Options/Accessories 1. Shutoff Valve: Provide process shutoff valve which can be used as an adjustable

pressure snubber.

2.5 SPARE INSTRUMENTS AND RELATED COMPONENTS

A. All spare equipment shall be packed in a manner suitable for long-term storage and shall be adequately protected against corrosion, humidity and temperature. Individually mark and vacuum seal all spare parts. Provide other spare parts as indicated on the individual device specifications.

PART 3 - EXECUTION



3.2 EXAMINATION




3.3 INSTALLATION

A. The General Contractor shall install all equipment per the manufacturer's recommendations and Contract Drawings.


C. All conduit entries into the instruments shall use hubs of watertight, threaded aluminum, insulated throat, stainless steel grounding screw, as manufactured by T&B H150GRA Series, or equal.


3.4 RACEWAY SEALING

A. Where raceways enter terminal boxes, junction boxes, or instrumentation equipment, all entrances shall be sealed with 3M 1000NS Watertight Sealant, or approved equal.



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3.6 FIELD ADJUSTING



3.7 FIELD TESTING




3.8 CLEANING






B. The General Contractor shall provide three (3) copies of the representative’s certification.

END OF SECTION

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I&C – ANALYTICAL DEVICES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13318 I&C - ANALYTICAL DEVICES.DOC

SECTION 13318 INSTRUMENTATION AND CONTROLS - ANALYTICAL DEVICES

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The General Contractor (GC) shall furnish, install and test all Analytical Instruments, process control devices and appurtenances, as shown on the Drawings, specified in the related work sections or divisions, and as specified herein.

B. Analytical Instruments specified in other divisions, shall be provided in accordance with this section and submitted as a part of the equipment specified in the other divisions.

1.2 SUBMITTALS

A. Refer to Section 13300

B. Submit catalog data for all items specified within this Section as applicable. Submittal shall include catalog data, functions, ratings, inputs, outputs, displays, etc., sufficient to confirm that analytical instrument provides every specified requirement. Any included options or exceptions shall be clearly indicated.

C. Submittals for equipment specified herein, as part of other sections or divisions, shall be made as a part of the equipment submitted under those sections or divisions.


A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. Calibration AVS 6.2, 6.4, 6.5 Hazardous Areas 2. IEC 79-10 Intrinsically Safe Circuits 3. 913 Electrical Instruments in Hazardous Atmospheres 4. Texas Commission on Environmental Quality rules


C. Each specified device shall inclusively conform to the standards and codes listed in the individual device paragraphs.


A. The manufacturer of this equipment shall have produced similar instrumentation equipment for a minimum period of five (5) years. When requested by the Owner and/or Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.



1.5 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for two (2) years from date of acceptance of the equipment containing the items specified in this Section. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition.

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Any warranty work requiring shipping or transporting of the equipment shall be performed by the GC at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MULTICHANNEL GAS MONITORING SYSTEM

A. The Gas monitoring system will provide for a centralized graphic display and alarming controller for up to four monitored 4-20mA channels. There will be three adjustable alarming set point levels provided per channel. Relay outputs are provided to allow control of beacons, horns per contract drawings.

B. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Scott Safety, 7400 Plus 2. Approved Equal

C. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety.

D. The controller shall be powered as shown on the drawings with the following power requirements: 1. AC powered: 100 to 240 VAC.

E. Functionality 1. The controller shall use a menu-driven operation system. 2. The controller display shall have graphic LCD display with backlit display bar graphs. 3. Temperature: -25DegC to 50DecC 4. Humidity: 0 – 90% H.H. non-condensing

F. Construction 1. Housing: NEMA 4X wall mount CSA certified for Class I, Division2, Groups A, B, C, D. 2. Six Relays rated at 5 amp 30 VDC or 250 VAC resistive Form C

2.2 HYDROGEN SULFIDE GAS DETECTOR

A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable: 1. MSA International Ultima XIR


C. General 1. Provide sufficient lengths of Manufacturer’s specialty cables for installation of power and

signal conductors as provided with each instrument.

D. Type 1. 316 Stainless Steel 2. Infrared dual-wavelength, Heated-Optics 3. Electronic, microprocessor based 4. Continuous, dual channel 5. Hydrogen Sulfide Level indicator

E. Function/Performance 1. Sense the presence of hydrogen sulfide gas prior to reaching toxic levels. 2. Provide early warning indication to personnel.

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3. Response Time: Less than 10 seconds to 90% of final reading from a step change in gas concentration.

4. Range: 0-50 PPM. 5. Alarm Settings: Field adjustable 6. Temperature Limits: 0 - 50° C (32 - 122° F). 7. Sensor Life: Three (3) years. 8. Minimum of two contacts to alert personnel of gas concentration levels. 9. Front mounted power-on and high alarm indicating lights. 10. Indicating meter graduated in Parts per Million (PPM) Hydrogen Sulfide. 11. Minimum two output contacts for remote indications 12. 4-20 mA output

F. Physical 1. Housing: Class 1, Div. 1, Groups A, B, C and D. 2. Infrared technology 3. Wall mounting with sensor remote from indicating transmitter 4. Shielded two-wire or three-wire sensor-to-controller wiring 5. Adjustable alarm setting 6. Local Indication

G. Power Requirements 1. 24vdc

H. Required Options/Accessories 1. Provide an integral indicator scaled in engineering units.

2.3 COMBUSTIBLE GAS DETECTOR

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. MSA International Ultima XIR 2. Honeywell 3. Scott Safety 4. Approved Equal


C. General

1. Provide sufficient lengths of Manufacturer’s specialty cables for installation of power and signal conductors as provided with each instrument.

D. Type 1. Infrared dual-wavelength, Heated-Optics. 2. Electronic, microprocessor based 3. Continuous, dual channel 4. Lower explosive level (LEL) indicator

E. Function/Performance: 1. Sense the presence of methane gas prior to reaching explosive levels 2. Provide early warning indication to personnel. 3. Response Time: Not more than 10 seconds to 90% of final reading from a step change in

gas concentration. 4. Range: 0-99 percent LEL. 5. Alarm Settings: Field adjustable. 6. Temperature Limits: 0 to 50 degrees C (32 to 122 degrees F). 7. Sensor Life: Three (3) years.

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8. Front mounted Power-On and High Alarm indicating lights. 9. Indicating meter graduated in percent LEL. 10. Analog 4-20 ma interface signal

F. Physical: 1. Housing: Class 1, Div. 1, Groups A, B, C and D. 2. Wall mounting with sensor remote from indicating transmitter. 3. Shielded two-wire or three-wire sensor-to-controller wiring. 4. Adjustable alarm setting.

G. Power Requirements

1. 24 volts DC Nominal.

H. Options/Accessories 1. Provide an integral indicator scaled in engineering units. 2. Provided 3/8 inch 316 Stainless Steel tubing for calibration and testing with sample gas

from the eye level mounting of the transmitter location. 3. Provide hand held programmer(s) where full setup is not available for the instrument

PART 3 - EXECUTION


A. Installer shall be specialized in installing this type of equipment with minimum 5 years documented experience

3.2 EXAMINATION




3.3 INSTALLATION

A. The GC shall install all equipment per the manufacturer's recommendations and Contract Drawings.

B. All process connections shall be 316 stainless steel tubing, 3/8” minimum, unless otherwise shown on the Drawings. Fittings shall be of the compression type, made of alloy 316 stainless steel.

C. All conduit entries into the instruments enclosures shall use hubs of watertight, threaded aluminum, insulated throat, incorporating a stainless steel grounding screw, as manufactured by T&B H150GRA Series.

D. Install stainless steel instrument labels with instrument ID, secured with stainless steel safety wire to each instrument transmitter and sensor element.

3.4 RACEWAY SEALING

A. Where raceways enter instruments, all entrances shall be sealed with 3M 1000NS Watertight Sealant.


A. Inspect installed instrumentation equipment for anchoring, alignment, electrical bonding and physical damage.

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B. Check tightness of all accessible process and electrical connections. Minimum acceptable values shall be as specified in the manufacturer's instructions.

3.6 FIELD ADJUSTING


B. Any field adjustments, required for proper system operation, shall be fully documented and included in the final O&M.

3.7 FIELD TESTING

A. Perform all field tests as specified in Section 13302 Instrumentation and Controls-Testing and as recommended by the manufacturers of the individual instruments.

B. Each test shall include but not be limited to individual interlocks for proper functionality.

3.8 CLEANING

A. Remove all rubbish and debris from inside and around the instrumentation equipment. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.




A. A qualified factory-trained and certified representative shall certify in writing that the equipment has been installed, adjusted, including all settings as defined in the contract documents, and is fully ready for use.

B. The GC shall provide three (3) copies of the representative’s certification.

END OF SECTION

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I&C – FIBER OPTIC DATA NETWORK Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13320 I&C - FIBER OPTIC DATA NETWORK.DOC

SECTION 13320 INSTRUMENTATION AND CONTROLS - FIBER OPTIC DATA NETWORK

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The General Contractor (GC) shall furnish, install, and test the fiber optic cables and accessories as shown on the drawings, and as specified herein.

B. Where shown on the drawings to terminate fiber optic cables in an existing patch panel the GC is responsible to verify that the type of connector as specified matches the existing enclosure and adequate space for the additions is present. If a discrepancy is found, the GC is to provide matching connections at no additional cost to the Owner as directed by the Engineer.

C. The Work includes the following: 1. Furnish all fiber optic cable, Fiber Optic Patch Panels (FOPP) as listed below and

other cable and wiring necessary to make the proper fiber optic connections to all the FOPP’s. The GC shall coordinate the landing, labeling, and documentation for all fibers within fiber optic patch panels whether provided by the GC or provided by others.

2. Install the fiber optic cables in accordance with the system manufacturer’s installation instructions. Coordinate, review the conduit and/or raceway layout and construction sequencing prior to installation, with the cable manufacturer to ensure conduit and/or raceway compatibility with the systems and materials being furnished. The work shall include furnishing, installing, testing, and landing all fiber optic cabling and connectors detailed in the following: a. FOC-SSCP (12 Strand, Multi-Mode) – Between the new Lime Stabilization

System Control Panel (SSCP) FOPP-SSCP, located outside at the Belt Press Building and the existing Network 19-inch Cabinet located within the Plant Pump Building MCC Room.

b. FOPP-SSCP – The GC shall provide, install and make operational a FOPP-SSCP within the Lime Stabilization System Control panel. The GC shall coordinate a location and sizing of FOPP-SSCP with the Lime Stabilization System Control Panel Vendor.

3. All fiber optic components shall be of the same manufacturer, makes and models wherever possible, so that system additions can be most easily integrated with respect to operation and maintenance training, spare parts inventory, and service contracts.

1.2 RELATED WORK

A. Related Sections: 1. Section 13300 I&C - General Provisions 2. Section 13302 I&C - Testing

1.3 SUBMITTALS

A. Submit to the Engineer for review and approval, in accordance with Division 1 and Section 13300, the following: 1. Complete manufacturer’s product data. Product data shall be provided for the fiber

optic cables, connectors, patch panels, spares and test equipment. Product data sheets shall include the manufacturer's name and catalog number for each item, the manufacturer's descriptive literature and catalog cuts, clearly marked to indicate the exact item submitted. The date of manufacture for each reel of cable shall be submitted. Cable with a manufacture date of greater than twelve (12) months previous to submittal date will not be acceptable.

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2. Certification of compliance in writing stating the fiber optic cable, anticipated layout, and components are compatible, acceptable for use and in compliance with these Specifications.

3. Complete layout and installation proposed which shows cable and conduit routing, materials, cable size and type, pulling lubricant being used, installation details, estimated maximum pulling tensions, overall system losses for each fiber, and any and all patch panel locations.

4. Resumes of the certified installation personnel who will actually conduct and supervise the installation, indicating the experience in the work specified under this section.

5. Training plan and schedule for fiber optic cable termination training. 6. Installation Test reports, including test equipment used, as specified. 7. Provide one (1) sample of each type of cable, and connector termination kit. Two (2)

samples of a completed example of each type of connector termination shall be submitted.

8. The GC shall provide a fiber optic power budget for each cable run in excess of 500 feet. The budget shall include transmitter power, receiver sensitivity, connector losses, cable losses and a 3db aging margin. Fiber optic transmission line shall maintain a minimum of 3db safety margin

9. Manufacturer’s Instructions.

B. Letter of Compliance with manufacturer’s installation standards


A. National Fire Protection Association (NFPA): 1. NFPA 70 - National Electrical Code (NEC) Article 770.

B. Underwriters Laboratories, Inc. (UL): 1. UL 1581 VW 1 - Vertical Tray Cable Flame Test 2. UL 1666 - UL Standard for Safety Test for Flame-Propagation Height of Electrical and

Optical-Fiber Cables Installed in Vertical Shafts. 3. UL 910 - UL Standard for Safety Test for Flame-Propagation and Smoke-Density

Values for Electrical and Optical-Fiber Cables Used in Spaces Transporting Environmental Air.

C. Institute of Electrical and Electronics Engineers (IEEE): 1. IEEE Standard 383 - Flame Retardant

D. Electronics Industry Association/Telecommunications Industry Association (EIA/TIA): 1. EIA-STD-RS-455 - Standard Test Procedures for Fiber Optic Fibers, Cables,

Transducers, Connecting and Terminating Devices

E. National Electrical Code Article 770, Optical Fiber Cable: 1. NFPA 70 2005

F. Fiber Optic Test Method and Instrumentation: 1. DOD-STD-1678

G. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. The fiber optic cabling system materials furnished under this section shall be provided by Fiber Optic suppliers who have been providing these types of material for the past three years. The Fiber Optic suppliers shall provide personnel capable of providing technical assistance and fiber testing during installation.

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B. The installation of fiber optic cabling system materials furnished under this section shall be performed by a certified fiber installer who has been installing these types of materials for the past three years.

C. All cabled optical fibers shall be 100% attenuated tested. The attenuation of each fiber shall be provided with each cable reel.

D. The cable manufacturer shall be ISO 9001 registered.

E. Cable with a manufacture date of greater than twelve (12) months previous to submittal date will not be acceptable.

F. The Engineer shall determine whether a product is an Approved Equal based upon the information listed herein and the manufacturer’s data sheets regarding the models specified. Alternate equipment must meet the criteria listed herein and any additional information in the manufacturer’s data sheets in order to be accepted as an Approved Equal. Supplier must furnish five working installation references for any alternate equipment along with owner, contact, and telephone number


A. The cable shall be packaged in cartons and / or wound on spools or reels. Each package shall contain only one continuous length of cable. The packaging shall be constructed so as to prevent damage to the cable during shipping and handling.

B. When the length of an order requires a large wooden reel the cable shall be covered with a three (3) layer laminated protective material. The outer end of the cable shall be securely fastened to the reel head so as to prevent the cable from becoming loose in transit. The inner end of the cable shall project into a slot in the side of the reel or into the housing on the inner slot of the drum, in such a manner and with sufficient length to make it available for testing.

C. Test tails shall be at least two (2) meters long. The inner end shall be fastened so as to prevent the cable from becoming loose during shipping and installation. Reels shall be permanently marked with an identification number that can be used by the manufacturer to trace the manufacturing history of the cable and fiber.

D. Reels shall be plainly marked to indicate the direction in which it shall be rolled to prevent loosening of the cable on the reel.

E. The attenuation shall be measured at 850 nm and 1300 nm for multimode fibers. The manufacture shall ship the test results along with the fiber optic cable.

F. Packaging: 1. The completed cable shall be packaged for shipment on non-returnable wooden reels.

It is the responsibility of the GC to determine all required cable lengths. 2. Top and bottom ends of the cable shall be available for testing. 3. Both ends of the cable shall be sealed to prevent the ingress of moisture. 4. Each reel shall have a weather proof reel tag attached identifying the reel and cable. 5. Each cable shall be accompanied by a Cable Data Sheet.

1.7 WARRANTY

A. The GC shall submit a warranty certificate from the equipment manufacturer. The manufacturer’s warranty period shall be concurrent with the GC’s for ten (10) years, commencing at the time of final acceptance by the Owner. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Manufacturer at no expense to the Owner.

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PART 2 - PRODUCTS

2.1 FULLY WATER BLOCKED FIBER OPTIC CABLE OUTSIDE PLANT TYPE

A. Manufacturers: 1. Subject to compliance with the contract documents, the following manufacturers are

acceptable: a. Mohawk division of Belden (Cooper Industries), Richmond, IN - AdvanceLite b. Corning Cable Systems, Hickory, NC – Altos c. Optical Cable Corporation, Roanoke, VA d. Approved Equal

2. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety.

B. Cable: 1. General:

a. Cables shall be outside plant loose tube, multimode types, as shown on the drawings and specified herein. All fiber optic cables shall be for outside locations meeting type OFN (Nonconductive optical fiber general purpose cable) as defined in article 770 of the NEC. Any fiber optic cables that are shown to be fully within indoor non process locations the cable shall be plenum rated meeting type OFNP (Nonconductive optical fiber plenums purpose cable). No Armored Cables shall be acceptable.

b. Each cable shall consist of individual 6 or 12 strand fiber groups, each fiber surrounded with water blocking compound, each individual 6 or 12 strand groups protected with a PBT (poly-butylene terephthalate) jacket and cabled around a rigid epoxy fiberglass central member. The cable shall be wrapped with a water swellable tape, aramid yarn and a UV resistant polyethylene jacket.

c. Cables shall be furnished in reel lengths, each long enough to reach from connection point to connection point without splice, utilizing the manufacturer’s published maximum reel length capability for each type and size to be used on this Project. If any length capability is insufficient to provide without splice, the shop drawing submittal shall clearly describe the insufficiency, and explain the location required for such a splice. Such exception must be described in detail, and approved by the Owner/Engineer before the cable is ordered. Installation of such splices without such approval will require removal of such cable and replacement with another manufacturer’s cable meeting the requirements of the location, all at no expense to the Owner/Engineer.

2. Optical fibers shall be placed inside a buffer tube. Each buffer tube shall contain up to 12 fibers.

3. Each fiber shall be distinguishable by means of color coding according to TIA/EIA-598-A, “Optical Fiber Color Coding.”

4. Buffer tubes containing fibers shall be color coded with distinct and recognizable colors according to TIA/EIA-598-A, “Optical Fiber Color Coding.”

5. In buffer tubes containing multiple fibers, the colors shall be stable across the specified storage and operating temperature range and not subject to fading or smearing onto each other or into the water blocking compound material. Colors shall not cause fibers to stick together.

6. Buffer tubes shall be kink resistant within the specified minimum bend radius of 12 inches.

7. Fillers may be included in the cable core to lend symmetry to the cable cross-section where needed.

8. The central anti-buckling member shall consist of a glass reinforced plastic rod. The purpose of the central member is to prevent buckling of the cable.

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9. The cable core shall contain a water-blocking material. The water blocking material shall be non-nutritive to fungus, electrically non-conductive and homogenous. It shall also be free from dirt and foreign matter and shall be readily removable with conventional nontoxic solvents. Cable shall contain water blocking threads between tubes.

10. The cable shall contain at least one ripcord under the sheath for easy sheath removal. 11. Tensile strength shall be provided by a combination of high tensile strength dielectric

yarns. 12. The high tensile strength dielectric yarns shall be helically stranded evenly around the

cable core. 13. The jacket or sheath shall be free of holes, splits and blisters. 14. The cable jacket shall contain no metal elements and shall be of a consistent

thickness. 15. Cable jackets shall be marked with manufacturers’ name, sequential meter or foot

markings, the year of manufacture, and a telecommunication handset symbol, as required by Section 350G of the National Electrical Safety Code (NESC). The actual length of the cable shall be within ±1 % of the length markings. The marking shall be in contrasting color with the cable jacket. The height of the marking shall be approximately 2.5 mm.

16. The maximum pulling tension shall be 2700 N (608 lbf) during installation (short term) and 600 N (135 lbf) long term installed.

17. The shipping, storage, and operating temperature range of the cable shall be -40° C to +70° C. The installation temperature range of the cable shall be -30° C to +70° C.

18. Fibers: a. All fibers in the cable must be usable fibers and meeting the required

specifications. b. Fibers shall conform to the following:

1) Cladding diameter: 125.0 ± 1.0 μm 2) Core-to-Cladding offset: 0.8 μm. 3) Cladding non-circularity: 1.0 %., defined as: {1 - (min. cladding dia. max.

cladding dia.)} x 100 4) Coating diameter: 245 ± 10 μm 5) Colored fiber diameter: nominal 250 μm. 6) Attenuation uniformity: No point discontinuity greater than 0.10 dB at either

1310 nm or 1550 nm. 7) Attenuation at the Water Peak: The attenuation at 1383 ± 3 nm shall not

exceed 2.1 dB/km 8) Cutoff wavelength: The cabled fiber cutoff wavelength (λccf) shall be <

1260 nm. 9) Mode-Field diameter: 9.30 ± 0.50 μm at 1310 nm 10.50 ± 1.00 μm at 1550

nm. 10) Zero dispersion wavelengths (λ0): 1301.5 nm λ0 1321.5 nm. 11) Zero dispersion slope (S0): 0.092 ps/ (nm2•km). 12) Fiber polarization mode dispersion (PMD): 0.5 ps/km 13) The coating shall be a dual layered, mechanically strippable, UV-cured

acrylate applied by the fiber manufacturer. 14) Required Fiber Grade - Maximum Individual Fiber Attenuation 15) (Multi-Mode Testing) the maximum dispersion shall be < 0.097 ps/

(nm•km) from 1332 nm to 1354 nm. 16) The fiber manufacturer shall proof-test 100% of the optical fiber to a

minimum load of 100 kpsi.

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2.2 FIBER TERMINATION CONNECTORS

A. Acceptable Manufacturers: 1. Subject to compliance with the contract documents, the following manufacturers are

acceptable: a. Corning Corp., Hickory, NC b. AMP, Inc., Harrisburg, PA c. A.P.D., Inc., Brooklyn, CT d. Approved Equal


B. Termination Connectors: 1. Provide ceramic ST style connectors for all fiber optic fibers. The connectors shall be

designed for use with 62.5/125 micron for multimode. Each connector shall cause a maximum signal attenuation of 0.5 dB. Connector specifications shall be as follows: a. Insertion loss (typical): 0.5 dB b. Durability (mating cycles): 1000 (minimum) c. Repeatability: Less than 0.2 dB d. Operating Temperature: - 40 to + 75° C with less than 0.3 DB change in

attenuation. e. Must Meet TIA/EIA 604 for intermittent ability f. No pre polished splice type connectors shall be used. All such connectors shall

be replaced at no increase to the contract cost or schedule to the Owner.

2.3 PATCH CABLES

A. Acceptable Manufacturers: 1. Subject to compliance with the contract documents, the following manufacturers are

acceptable: a. Corning Corp., Hickory, NC b. AMP, Inc., Harrisburg, PA c. A.P.D., Inc., Brooklyn, CT d. Approved Equal


B. Fiber Optic Patch Cables with pre-installed Connectors: 1. Fiber optic patch cable shall be 2 fiber zip cord 62.5/125 micron for multimode riser

rated cable to match the fiber to be patched. 2. Installation of patch cables shall include all spares and observe the minimum fiber

bend radius and strain relief. 3. Provide ceramic style connectors for all fiber patch cable connections. 4. Termination type shall match the equipment and connection type as installed. 5. The connectors shall be designed for use with 62.5/125 micron for multimode, and

shall be capable of operating in a range of 0 to 60° C. 6. Each connector shall cause a maximum signal attenuation of 0.5 db. 7. All fiber optic cables shall be tested for performance and loss after termination and

installation to verify that at least a 3 dB power safety margin is obtained between all transmitters and receivers.

8. Test data for each fiber and safety margin calculations for each fiber path shall be provided to the Owner and Engineer after installation to verify conformance with this specification.

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2.4 CABLE MARKING SYSTEMS

A. A 7-mil, flame retardant, cold and weather-resistant vinyl plastic electrical tape shall be used for individual cable in panel identification, 3M Corp.; Scotch 35 Tape. Tape shall be applied a minimum of 5 wraps every foot within enclosures.

B. Cable tags shall be heat stamped nylon secured by polypropylene cable ties, Thomas & Betts No.TC228-9. Tag shall be installed on each cable within one foot of patch panel.

C. All Patch panels shall be marked with nameplates. Each cable by name as shown on the drawings that terminates within the patch panel shall be included on the nameplate. Nameplates shall be engraved, laminated impact acrylic, matte finish, black lettering on a white background, not less than 1/16-in thick by 1/2-in by 1-1/2-in, Nameplates shall be attached to the door of Patch panel with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”, no equal. Prior to installing the nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residues has been removed. Epoxy adhesive or foam tape is not acceptable.

2.5 PATCH PANELS AND ENCLOSURE SYSTEMS

A. Patch panels shall be used for all cable termination points. All strands shall be terminated to a connecter on a Closet Connector Housing (CCH) panel.

B. Patch panels for use in 19” equipment rack enclosures shall be the rack-mountable version of the LANscape series as manufactured by Corning Incorporated unless otherwise shown in the drawings.

C. Patch panels for use in PLC control panel enclosures shall be the Wall-mountable Interconnect Center (WIC) type, LANscape series, as manufactured by Corning Incorporated unless otherwise shown in the drawings

D. All fiber cables shall be terminated to a patch panel with a Fan out kit. The Model shall be as recommended by the cable manufacturer.

2.6 HDPE RACEWAY (INNERDUCT)

A. Provide UL Listed HDPE nonmetallic flexible raceway manufactured from High Density Polyethylene as specified herein. HDPE Raceway shall be suitable for underground and/or innerduct applications to protect fiber optic cables. The HDPE raceway shall be compliant with NEC Article 353 and be manufactured to UL 651 specifications.

B. Minimum size shall be one and a quarter inch with smooth outer wall and a ribbed inner surface.

C. Acceptable manufacturers are Blue Diamond Company or Innerduct Company.

D. Innerduct shall be used in all fiber optic cable runs below grade full the complete run.

2.7 PULLING COMPOUNDS

A. Pulling compound shall be nontoxic, nonflammable, noncombustible and non-corrosive. The material shall be UL listed and compatible with the cable insulation and jacket.

B. Acceptable manufacturers are Ideal Company; Polywater, Incorporated or Cable Grip Co.

2.8 FACTORY TESTING

A. Perform manufacturers standard production testing and inspection in accordance with Section 6 of the referenced ICEA standards. If requested by the Owner/Engineer, the manufacturer shall submit certified proof of compliance with ICEA design and test standards.

B. Provide certified test reports indicating that the cable has passed the following tests:

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1. Partial Corona Discharge Test in accordance with ICEA S-97-682 Section 9.13. 2. Vertical tray flame test in accordance with IEEE 1202

C. After completion of the factory tests, individual pulling eyes shall be installed on individual lengths of cable. Pulling eyes shall be suitable for maximum allowable pulling tension on the cables and shall be sealed against entrance of water. A common pulling eye shall not be applied.

PART 3 - EXECUTION

3.1 GENERAL

A. GC to determine the cutting lengths, reel arrangements and total lengths of cable required and shall furnish this data to the cable manufacturer as soon as possible to assure on-time delivery of cable.

B. Splicing and terminating shall be performed by experienced workmen having formal training and current certifications with a minimum of 3 years field experience in this type of fiber termination work.

C. The GC shall provide a Certificate of Training issued within the last two years for the installers preforming the work.

3.2 MANUFACTURER’S REPRESENTATIVE

A. The GC shall provide the services of a cable manufacturers certified installation specialist to be present during the installation of all sections of the cable. The manufacturer shall provide a report to the Owner at the conclusion of the installation that the installation tools and termination materials were of types acceptable to the cable manufacturer, and to his knowledge, he observed no procedures that were contrary to the recommended installation procedures recommended by the Manufacturer. The report shall be signed by the manufactures specialist and the GC.

3.3 CABLE INSPECTION

A. Perform the following inspections in the presence of the Owner/Engineer: 1. Verify that fiber optic cable reels have been off-loaded from truck carefully and not

damaged. 2. Submit to the Engineer all test data provided by the fiber manufacture. 3. Verify that the optical fibers of the cable assembly are the type and quantity as

specified and as recommended by the Instrumentation System Supplier. 4. Verify that cable construction is the type specified.

3.4 INSTALLATION

A. Cable Installation: 1. All cable indoor and outdoor shall be installed in conduits. Cables shall not be direct

buried. 2. When temperature is below 50° F, cable reels shall be stored at 70° F for at least 24

hours before installation. 3. Inspect raceway prior to pulling cables. Notify the Owner/Engineer of any conditions

which would prevent installation of the specified cables, before proceeding with the installation. Rod and swab out ducts prior to installing cables.

4. Pull cables prior to attachment of connectors. 5. All cable installation shall be installed with tension-monitoring equipment, using a

tension monitoring recorder. Where conductors are found to have been installed without tension–monitoring, the cables, including any existing or previously installed in

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the same raceway under this contract, shall be immediately removed from the raceways, permanently identified as rejected material, and removed from the jobsite. New cables shall be reinstalled and tagged, all at no expense to the Owner.

6. Lubricate cables with lubricants specially formulated for fiber cabling jackets during installation. Do not exceed cable manufacturer’s specifications for tensile strength and bending radius. Pulleys used to aid in the installation of the fiber optic cable must be sized according to the minimum bending radius. The pulling tension of all fiber cables during installation shall be recorded using a strip recorder. The printout of the strip recorder shall be submitted to the Engineer.

7. Do not exceed manufacturer's recommendations for maximum pulling tensions and minimum bending radii. The GC shall submit such information to the Owner/Engineer, and the information shall be available at the project site.

8. Pull cables by directly pulling only on the strength member. 9. Support cables in riser conduits at intervals as required by National Electric Code. 10. Within manholes, protect cable by providing flexible, corrugated, polyethylene slit duct.

Connect slit duct to duct bank by using hose clamps. Support duct at ten (10) foot intervals.

11. Feed cables into raceway with zero tension and without cable crossover at raceway entrance

B. Cable Splicing: 1. Do not make splices in cable unless approved by the Owner/Engineer. Splices shall be

made in designated enclosures above ground only. Provide adequate put up lengths on cable reels to make termination to termination runs without splices. Where splices are unavoidable, subject to the approval of the Owner/Engineer, provide fusion splices with attenuation losses of 0.3 dB or less. Make splices watertight and provide mechanical protection equal to the cable jacket, or better.

2. The work area shall be kept warm, dry and ventilated during splicing and terminating of the cables.

C. Cable Termination: 1. Installation tools and termination material shall be as approved by the cable

manufacturer. 2. Install breakout kits, signal transceivers, power supplies, patch panels, pigtails and

jumpers as required and as indicated to install a complete data highway communications network. Patch panels and splice enclosures shall be wall mounted unless otherwise shown.

D. Marking and Identification: 1. Plastic nameplates shall be installed in each manhole, pull box and at splice and

terminating points. These nameplates shall show the cable designations and the date when the cable was installed or splice or termination was made. The cable designation shall be as indicated on the drawings. Nameplates shall be tied to each cable with self-locking stainless steel ties.

2. Label each cable, buffer tube and fiber with permanent waterproof typewritten tags.

3.5 PHYSICAL CHECKOUT

A. General Procedures: 1. Conduct physical checkout of the fiber optic data highway network. 2. Physical checkout shall be performed prior to functional testing.

B. Check Procedures: 1. Submit to the Engineer all test data provided by the fiber manufacture. 2. Verify that the optical fibers of the cable assembly are the type and quantity as

specified and as recommended by the GC. 3. Verify that cable construction is the type specified.

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4. Verify that fiber optic patch panels have been installed plumb and level at locations indicated.

5. Verify that optical fiber connections or terminations within patch panels and splice closures are in accordance with cable manufacturer's recommendations.

6. Verify that all optical fiber terminations are within patch panels and dust plugs are installed on all unused connections.

3.6 FIELD AND FUNCTIONAL TESTING

A. Make the following site tests before removing cable from cable reels: 1. Determine attenuation losses of each fiber from end to end. Use an optical time

domain reflect-o-meter (OTDR) to capture and record. Provide a printout of the captured data.

2. Submit to the Engineer all test data and models of test equipment, calibration standards and tests.

B. Make the following field tests after cable and connector installation: 1. All fiber optic cables shall be tested for performance and loss after cable installation

and connector termination to certify that at least a 3dB power safety margin is obtained between all transmitters and receivers. Test data for each fiber and safety margin calculations for each fiber path shall be submitted to the Owner and Engineer after installation to verify conformance with this specification. The following tests shall be performed as a minimum but not limited to:

2. Visually, inspect terminal connectors for out of round condition and surface defects such as microchips and cracks using a 200X (minimum) inspection microscope.

3. Check optical continuity of each fiber from terminal to terminal. Use test equipment as specified herein and provide typewritten report certifying each fiber in every cable.

4. Verify the calculated attenuation power losses of each fiber from both transmit and receive terminals of each data communications loop (both directions). The light source and operating wavelength of the test equipment shall be 850nm and 1300nm for multimode strands. Use an OTDR.

5. Record and Submit the actual installed length as verified utilizing an OTDR.

C. Owner/Engineer will observe the testing. Inform Owner/Engineer of testing schedule at least one week prior to start of testing.

D. Equipment testing and inspection for all new cables shall be performed in accordance with the manufacturer’s recommendations on a generic form, and shall include the following:

END OF SECTION

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I&C – CONTROL PANELS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13325 I&C - CONTROL PANELS.DOC

SECTION 13325 INSTRUMENTATION AND CONTROLS - CONTROL PANELS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish and install fully functional control panels to manually and automatically operate control systems as specified in the detailed requirements of the instrumentation sections of Division 13, and supplemented with logic and schematics diagrams as shown on the Electrical and Instrumentation Drawings.

B. It is the intent of these specifications to have all I/O and signal conditioning components included within their respective control panels. The panel sizes listed herein shall be considered minimum. The General Contractor (GC) shall be responsible for final sizing of enclosures to meet the clearance requirements of NFPA 79, the NEC and as specified herein. Should the GC submit a panel size and layout that is, in the opinion of the Owner and/or Engineer, insufficient in size to meet these requirements, the submittal will not be approved and will be returned for revision and resubmission. The GC shall be required to revise the panel size and layout and resubmit for approval at no additional cost to the Owner.

C. Control panels as specified in the Process Equipment Division, Electrical Equipment Division or Mechanical Equipment Divisions, except as specifically stated herein shall not be submitted under this section.

D. All enclosures and panel components shall be of the same manufacture wherever possible.

E. The GC shall furnish all labor necessary for the installation and testing as required to fully meet the applicable specifications of this equipment.

F. The following panels shall be furnished by the GC. Each panel shall be supplied with full back panels. The Contractor shall be responsible for furnishing any and all control panels shown in the Drawings but not included in the following listing.

PANEL ID ENCLOSURE RATING

PANEL LOCATION MINIMUM ENCLOSURE SIZE

Gas Alarm Control Panel (GAP)

NEMA 4X, stainless steel, Window Door,

Wall Mount

Belt Press Building Second Floor 24”H x 24”W x 12”D

Beacon/Alarm Control Panel No.1

(Downstairs)

NEMA 4X, stainless steel, Wall Mount

Belt Press Building 1st Floor 12”H x 12”W x 8”D

Beacon/Alarm Control Panel No.2

(Outside)

NEMA4X, stainless steel, Wall Mount

Belt Press Building 2nd Floor Outside

Stairs

12”H x 12”W x 8”D

Plant Water Low Level Relay Panel

(LLRP-PW)

NEMA4X, painted steel, Wall Mount

Plant Pump Building MCC Room

GC shall size as required

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1.2 RELATED WORK


B. Section 13327 I&C - Panel Mounted Equipment

1.3 SUBMITTALS

A. Submittal Process: 1. Submittals shall be made in accordance with the requirements of Section 13300, and

as additionally specified herein. 2. Submittals require information on related equipment to be furnished under this

Specification, and described in the related sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will be returned un-reviewed.

3. Equipment specified in Process, Mechanical, or Electrical Equipment Divisions, and supplied as an integral part of a process equipment manufacturer’s package shall be submitted with the manufacturer’s submittals, in those Divisions.

B. Submittal Content: 1. The GC shall create equipment shop drawings, including all wiring diagrams, in the

GC’s engineering department. All equipment shop drawings shall bear the GC logo, drawing file numbers, and shall be maintained on file in the original equipment manufacturer’s archive file system. Photocopies of the Engineer’s ladder schematics are unacceptable as shop drawings.

C. Required Submittals: 1. Copies of previously approved related work submittals 2. Documentation confirming that the Panel Assembly Facility is a UL-508 certified panel

shop 3. Facsimile of the UL label that is to be applied to each of the completed panels 4. Shop Drawings:

a. Shop Drawings shall include the following: 1) Drawings shall be to scale and shall show the location of panel mounted

devices, including doors, and sub panels. 2) Equipment outline drawings showing elevation, plan and interior views,

front panel arrangement, dimensions, weight, shipping splits, conduit entrance points and anchor bolt pattern. Indicate all options, special features, ratings and deviations from this section’s requirements.

3) The first sheet of each Panel Drawing Packet shall contain a Bill of Materials for that panel. The Bill of Materials shall list all devices mounted within the panel, and shall include the tag number, description, manufacturer, and model number of each item.

4) Following the Bill of Material shall be a listing, uniquely identifying each component of the Panel, and a description of the item used, i.e. devices by their assigned tag numbers, nameplate inscriptions, service legend, and annunciator inscriptions.

5) Include power and control schematics with external connections. Show wire and terminal numbers and color-coding.

b. Interconnecting Wiring Diagrams: 1) Provide interconnecting wiring diagrams showing electrical connections

between equipment, consoles, panels, terminal junction boxes, and field mounted components.

2) Diagrams shall show component and panel terminal board identification numbers, and external wire and cable numbers.

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3) Circuit names corresponding to the Circuit and Raceway Schedule shall be shown. The diagram shall include intermediate terminations between field elements and panels (e.g., terminal junction boxes, pull boxes, etc.)


A. Instrumentation equipment, materials and installation shall comply with the National Electrical Code (NEC and with the latest edition of the following codes and standards: 1. NEMA ICS 6 Enclosures for Industrial Controls and Systems 2. Underwriters Laboratories (UL) 3. UL 508, the Standard of Safety for Industrial Control Equipment 4. UL 508A, the Standard of Safety for Industrial Control Panels 5. NEMA ICS 4 Terminal Blocks for Industrial Use. 6. NEMA LS1 Low Voltage Surge Protection Devices 7. All equipment and installations shall conform to applicable Federal, State, and local

codes.


A. The manufacturer of this equipment shall have produced similar equipment for a minimum period of five (5) years. When requested by the Owner or Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

B. The control panels shall be assembled in a UL-certified panel shop, experienced in the assembled of control panels for water and waste water treatment systems. A submittal of the documentation, that certifies the panel fabrication shop is a UL-certified shop, is required.

C. Equipment components and devices shall be UL labeled wherever UL standards exist for such equipment. The completed control panel shall be UL Labeled in accordance with UL 508 and or 508A as applicable. The panel shall be UL labeled for the environment in which it is to be placed. A UL label shall be affixed to the inside of the external door by the panel fabrication assembly shop. Submit a facsimile of the UL label in the submittal information.

D. Equipment submitted shall fit within the space shown on the drawings. Equipment which does not fit within the space is not acceptable.

1.6 DELIVERY STORAGE AND HANDLING

A. Completed control panels and related equipment shall be handled and stored in accordance with manufacturer's instructions. Two (2) copies of these instructions shall be included with the equipment at time of shipment, and shall be made available to the general contractor, the Owner and Engineer.

B. Shipping groups shall be designed to be shipped by truck, rail, or ship. Indoor groups shall be bolted to skids. Accessories shall be packaged and shipped with each panel.

C. Visible shipping damage to any portion of a shipment shall be assumed to have also damaged the surrounding portion. The visibly damaged and the surrounding panels shall be returned to the manufacturer’s UL 508 facility, for examination and damaged equipment replaced, followed by a Witnessed Test of the returned portion, as specified in Section 13302, at no expense to the Owner or Engineer.

D. Control Panels shall be installed in their permanent finished location shown on the drawings within seven (7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7) calendar days, the equipment shall not be delivered to the site, but stored offsite, at the contractor’s expense, until such time that the site is ready for permanent installation of the equipment.

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E. Space heaters shall be furnished in control panels and the contractor shall provide temporary electrical power and operate space heaters during storage, and after equipment is installed in permanent location, until equipment is placed in service.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 2 years with terms as further defined in section 13300.

PART 2 - PRODUCTS

2.1 MATERIAL MANUFACTURERS

A. Subject to compliance with the contract documents, the following electrical material manufacturers are acceptable: 1. Hoffman 2. EMF 3. Approved Equal

B. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Materials Manufactures listed above are not relieved from meeting these Specifications in their entirety.

C. Manufactures of all related devises and components shall be as specified elsewhere in related work specifications

2.2 RATINGS

A. The complete control panel assembly shall be UL certified or carry a UL 508A listing for "Industrial Control Panels".

B. The control panel shall meet all applicable requirements of the National Electrical Code.

C. All devices unless otherwise specified shall be designed for continuous operation at rated current in a 40 degree C ambient temperature

D. For additional ratings and construction notes, refer to the drawings.

E. The service voltage shall be as specified and as shown on the drawings. The overall short circuit withstand and interrupting rating of the equipment and devices shall be equal to or greater than the overall short circuit withstand and interrupting rating of the feeder device immediately upstream of the Control Panel, but not less than 10,000 amperes RMS symmetrical at 120 volts single phase.

2.3 CONSTRUCTION

A. General: 1. Refer to the drawings for: schematics, actual layout and location of equipment and

components; current ratings of devices, bus bars, components; protective relays, voltage ratings of devices, components and assemblies; and other required details.

B. Enclosures: 1. General:

a. Each enclosure shall incorporate a removable back panel, on which control components shall be mounted. Back panel shall be secured to the enclosure with collar studs for wall mounted enclosures, and 316 SS hardware for free standing enclosures.

b. All free standing enclosures shall be provided with feet of the same construction as the enclosure.

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c. Back panel shall be tapped to accept all mounting screws. Self-tapping screws shall not be used to mount any components.

d. All enclosure doors shall have bonding studs. The enclosure interior shall have a bonding stud.

e. Each enclosure shall be provided with a documentation pocket on the inner door. f. Enclosures shall not have holes or knockouts. g. Provide manufacturer’s window kits where shown on the drawings. h. All panels installed outdoors shall have a factory applied, suitable primer and final

coat of weatherproof white paint. i. All enclosures shall be lockable, and keyed alike.

2. NEMA 4X: a. Where an enclosure is not otherwise defined or shown on the drawing:

1) NEMA 4X 316 Stainless Steel 2) Type 316 stainless steel, body and door 3) Stainless steel continuous hinge 4) Foam in-place gasket 5) Single point quarter turn latches (20”x24” and below). All others 3-point

latch b. Manufacturers:

1) Hoffman Concept Series 2) EMF Company 3) NEMA Enclosures Company 4) Hammond Company

C. Environmental Controls: 1. Enclosure Condensate Heaters:

a. A self-contained enclosure condensation heater with thermostat and fan shall be mounted inside the control panel, if panel is to be installed outdoors or in a non-air-conditioned space: 1) Enclosure heaters shall be energized from 120 volt, single-phase power

supply and sized to prevent condensation within the enclosure. 2) Locate enclosure heaters to avoid overheating electronic hardware or

producing large temperature fluctuations on the hardware. 3) Enclosure heaters shall have an internal fan for heat distribution and shall

be controlled with adjustable thermostats. The thermostat shall have an adjustment range of 40 degrees Fahrenheit to 90 degrees Fahrenheit. Provide a circuit breaker or fused disconnect switch within the enclosure.

4) Enclosure heaters shall be Hoffman type DAH. 2. Corrosion Protection:

a. Provide corrosion protection in each control panel with a corrosion-Inhibiting vapor capsule as manufactured by Northern Instruments; Model Zerust VC, or Hoffman Engineering; Model A-HCI.

2.4 PANEL EQUIPMENT

A. Equipment Requirements: 1. The requirements for equipment, controls, meters, converters, etc., for each Control

Panel, shall be as shown on the Panel Schedule herein, the drawings, panel schematics, and the functions specified in the control narratives sections of the specifications.

2. Where communications equipment is designed as part of the control panel, the equipment shall be as specified in Section 13515 Communications Interface Equipment.

3. Where fiber optic equipment is designed as part of the control panel, the equipment shall be as specified in Section 13320 Fiber Optic Data Network.

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4. All other equipment, controls, meters, converters that are designed as a part of the control panel, shall be as specified in Section 13327 Panel Mounted Equipment and the Related Work Sections specified herein.

5. Furnish installed in each Control Panel, a dedicated Surge Protective Device (SPD) (UL 1449 Type 3), permanently connected, on the load side of the power entrance, as specified in Section 13327 Panel Mounted Equipment.

6. Provide a main circuit protective device, DIN rail mounted, to protect the panel equipment with an external cable actuated lockable disconnected means.

B. Panel Control Device Requirements: 1. Control Devices and Indicators:

a. All operating control devices, indicators, and instruments shall be securely mounted on the panel door. All controls and indicators shall be 30mm, corrosion resistant, NEMA 4X, anodized aluminum or reinforced plastic. Booted control devices are not acceptable. Auxiliary contacts shall be provided for remote run indication and indication of each status and alarm condition. Additional controls shall be provided as specified herein and as required by the detailed mechanical and electrical equipment requirements.

b. Indicator lamps shall be LED type. For all control applications, indicator lamps shall incorporate a push-to-test feature. Lens colors shall be as follows: 1) Red for RUNNING, Valve OPENED, and Breaker CLOSED. 2) Green for OFF, Valve CLOSED, and Breaker OPEN 3) Amber for FAILED 4) Blue for READY 5) White for POWER ON

c. Mode selector switches (HAND-OFF-AUTO, LOCAL-OFF-REMOTE, etc.) shall be as shown on the drawings. Units shall have the number of positions and contact arrangements, as required. Each switch shall have an extra dry contact for remote monitoring.

d. Pushbuttons shall be as follows: 1) Red for STOP, Valve OPEN, Breaker CLOSE, and mushroom Red for

EMERGENCY STOP 2) Green for START, Valve CLOSE, and Breaker OPEN 3) Black for RESET

e. Furnish nameplates for each device. All nameplates shall be laminated plastic, black lettering on a white background, attached with stainless steel screws. Device mounted nameplates are not acceptable.

2. A failure alarm with horn and beacon light shall be provided when required or specified. Silence and reset buttons shall be furnished. Alarm horn and beacon shall be by Federal Signal or Crouse-Hinds, NEMA 4X for all areas except for NEMA 7 areas, which shall be NEMA 7/4X cast aluminum.

3. Control and Instrument Power Transformers: a. Control power transformers shall be provided where shown on the drawings.

Transformer shall be sized for the entire load, including space heaters, plus 25% spare capacity, and shall be not less than 100VA.

b. Control power transformers shall be 120 volt grounded secondary. Primary side of the transformer shall be fused in both legs. One leg of the transformer secondary shall be solidly grounded while the other leg shall be fused.

2.5 EQUIPMENT INSTALLATION

A. Equipment Mounting: 1. The location of the installed equipment shall be as shown on the Panel Layouts on the

drawings. 2. Each piece of equipment shall be securely mounted to the back plate or side plate in

accordance with the manufacturer’s installation instructions. All mounting hardware

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shall be from the front of the back plate or side plate with threaded screws. Attaching hardware shall not be installed from the rear of the back plate or side plate. Removal of any piece of equipment shall not require the removal or loosening of any other piece of equipment.

3. Operator interface equipment installed on the door shall be arranged as shown on the drawings in accordance with the manufacturer’s installation instructions. No penetrations of the door shall be made except for equipment mounting. Provide adequate clearance between pieces of equipment and door latching mechanisms.

B. Nameplates: 1. External:

a. Nameplates shall be engraved, laminated impact acrylic, matte finish, not less than 1/16-in thick by 3/4-in by 2-1/2-in, Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures except for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”. Prior to installing the adhesive nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residues has been removed. Epoxy adhesive or foam tape is not acceptable: 1) There shall be a master nameplate that indicates supply voltage equipment

ratings, short circuit current rating, manufacturer's name, shop order number and general information. Cubicle nameplates shall be mounted on the front face, on the rear panel and inside the assembly, visible when the rear panel is removed.

2) Provide permanent warning signs as follows: a) "Danger- High Voltage- Keep Out" on all doors where any voltage

over 125 volts AC is present.. b) "Warning- Hazard of Electric Shock - Disconnect Power Before

Opening or Working On This Unit" on main power disconnect or disconnects.

2. Internal: a. Provide the panel with a UL 508A label. b. Control components mounted within the assembly, such as fuse blocks, relays,

pushbuttons, switches, etc., shall be suitably marked for identification, corresponding to appropriate designations on the submitted and reviewed wiring diagrams.

3. Special: a. Identification nameplates shall be white with black letters, caution nameplates

shall be yellow with black letters, and warning nameplates shall be red with white letters.

C. Wiring Trough and Terminal Block Installation: 1. Space between wiring troughs and equipment shall be such that space for terminal

blocks is provided for termination of each conductor or group of conductors before connection to the equipment. Removal of equipment for service shall not leave any exposed conductors hanging unconnected.

2. Install the wiring troughs such that one may be removed without interference from the other. Troughs shall be installed such that trough covers may be removed without cover interference.

3. Install terminal blocks on DIN rail with adequate space for access to the terminal with clear view of the wire identification label. All incoming or outgoing wiring shall enter or leave the panel on terminal blocks. Terminal blocks or wiring troughs shall not be installed on the doors. Provide terminal blocks on side plates and back plates for all door mounted equipment.

4. In no case shall internal and external wiring share a wiring trough. 5. Provide 600 volt rated terminal blocks for any conductor carrying any voltage over 120

volts to ground.

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6. Provide 600 volt rated strap screw terminal blocks for any power conductors carrying over 20 amps, at any voltage. Terminals shall be double sided and supplied with removable covers to prevent accidental contact with live circuits.

7. Power conductors carrying over 20 amps, at any voltage shall be terminated to strap-screw type terminal blocks with crimp type, pre-insulated, ring-tongue lugs. Lugs shall be of the appropriate size for the terminal block screws and for the number and size of the wires terminated. Do not terminate more than one conductor in any lug, and do not land more than two conductors under any strap-screw terminal point.

8. Terminals shall have permanent, legible identification, clearly visible with the protective cover removed. Each terminal block shall have 20 percent spare terminals, but not less than two spare terminals.

9. Do not land more than two conductors per terminal point. Use the manufacturer’s provided bridge connectors to interconnect terminal blocks terminating common or ground conductors.

10. Twisted shielded pair or triad cables shall have each individual conductor and shield drain wire landed on individual terminal blocks. Use the manufacturer’s provided bridge connectors to interconnect terminal blocks terminating the shield drain wire conductors.

11. Provide an AC ground bar bonded to the panel enclosure, if metal, with 20 percent spare terminals.

12. Provided ground terminal blocks for each twisted-shielded pair drain wire.

D. Internal Panel Wiring: 1. Power and control wiring shall be tinned stranded copper, minimum size No. 14 AWG,

with 600 volt, 90 degree C, flame retardant, Type MTW thermoplastic insulation. Line side power wiring shall be sized for the full fault current rating or frame size of the connected device, and as shown on the drawings.

2. Analog signal wires shall be 600 Volt Class, insulated stranded tinned copper, twisted shielded #16 AWG pair.

3. All interconnecting wires between panel mounted equipment and external equipment shall be terminated at numbered terminal blocks. Field wiring shall not be terminated directly on any panel-mounted device.

4. All wiring shall be tagged and coded with an identification number as shown on the drawings. Coding shall be typed on a heat shrinkable tube applied to each end showing origination and destination of each wire. The marking shall be permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE.

5. All wiring shall be enclosed in PVC wire trough with slotted side openings and removable cover. Plan wire routing such that no twisted shielded pair cable conducting analog 4-20 mA signals or low voltage analog signals are routed in the same wire trough as conductors carrying discrete signals or power.

6. Control panel wire color code shall be as follows: a. Black: AC power at line voltage b. Red: switched AC power c. Orange: May be energized while the main disconnect is in the off position d. White: AC neutral e. Orange/white stripe or white/orange stripe: separate derived neutral f. Red/white stripe or white/red stripe: switched neutral g. Green or green w/ yellow tracer: ground/earth ground h. Blue: Ungrounded DC power i. Blue/white stripe or white/blue stripe: DC grounded common j. Brown: 480V AC 3 phase - phase A k. Orange: 480V AC 3 phase - phase B l. Yellow: 480V AC 3 Phase - phase C m. Purple: common for analog signal wiring n. Brown: positive leg of an analog signal

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E. Field Entrance Internal Wiring: 1. Field entrance internal wiring shall be neatly grouped by circuit and bound by plastic

tie wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring.

2. All field wiring shall be tagged and coded with an identification number. Coding shall be typed on a heat shrinkable tube applied to each end of the wire. The marking shall be a permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE.

3. All conduit entering or leaving equipment shall be coordinated, in advance with the panel installer, so that the conduit entrances to the enclosure are directly below the termination area for immediate termination. Conduits shall not enter the top or side of the panel unless approved in writing by the Owner and Engineer.

F. Fusing of PLC Inputs and Outputs: 1. All PLC analog inputs and outputs shall be individually fused for each channel. All

discrete inputs and outputs shall be buffered with relays from the field connections. Discrete points shall be fused for each circuit group with no less than one fuse per PLC I/O card.

PART 3 - EXECUTION


A. Installer shall be specialized in installing this type of equipment with minimum 5 years documented experience. Experience documentation shall be submitted for approval prior to beginning work on this project.

3.2 EXAMINATION


B. Housekeeping pads shall be included for the floor mounted panels as detailed on the drawings.

C. Check concrete pads and baseplates for uniformity and level surface.

D. Verify that the equipment is ready to install.

E. Verify field measurements are as instructed by manufacturer.

3.3 INSTALLATION

A. The contractor shall install all equipment per the manufacturer's recommendations and contract drawings.

B. Conduit hubs for use on raceway system pull and junction boxes shall be watertight, threaded aluminum, insulated throat, stainless steel grounding screw, as manufactured by T&B H150GRA Series.

C. Conduits entering a control Panel or box containing electrical equipment shall not enter the enclosure through the top.

D. Install required safety labels.

3.4 RACEWAY SEALING

A. Where raceways enter junction boxes or control panels containing electrical or instrumentation equipment, all entrances shall be sealed with 3M 1000NS Watertight Sealant.

B. This requirement shall be strictly adhered to for all raceways in the conduit system.

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B. Check tightness of all accessible electrical connections. Minimum acceptable values are specified in manufacturer's instructions.

C. Provide laminated copies of the Control schematics in each enclosure door pocket.

3.6 CLEANING

A. Remove all rubbish and debris from inside and around the panel. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.



END OF SECTION

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I&C – PANEL MOUNTED EQUIPMENT Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13327 I&C - PANEL MOUNTED EQUIPMENT.DOC

SECTION 13327 INSTRUMENTATION AND CONTROLS - PANEL MOUNTED EQUIPMENT

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. This section of the specifications describes the requirements for miscellaneous equipment to be furnished under other sections of the specifications as listed in the related work paragraph of this section.

B. All equipment described herein shall be submitted and furnished as an integral part of equipment specified elsewhere in these Specifications.

1.2 RELATED WORK

A. Section 13300 I&C - General Provision

1.3 SUBMITTALS

A. Refer to specification section 13300.


A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA/ISCI 109 Transient Over voltage Withstand Test 2. IEEE Std. 472/ANSI C37.90.2 Withstand Capability of Relay Systems to Radiated

Electromagnetic Interference from Transceivers. 3. IEC 255.4 Surge Withstand Capability Tests 4. NEMA/ICS 1 General Standard for Industrial Control Systems 5. NEMA/ICS 4 Terminal Blocks for Industrial Use. 6. NEMA/ICS 6 Enclosures for Industrial Control Systems 7. NEMA LS 1 Low Voltage Surge Protective Devices 8. UL 1449 Third Edition – Surge Protective Devices

B. All equipment shall comply with the requirements of the National Electric Code and Underwriters Laboratories (UL) where applicable.


PART 2 - PRODUCTS

2.1 MODE SELECTOR SWITCHES, PUSHBUTTONS AND INDICATING LAMPS

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Allen Bradley 2. Cutler Hammer 3. GE 4. Square D 5. Approved Equal


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C. Construction: 1. 30mm Diameter 2. Corrosion resistant 3. NEMA 4/4X/13 without booted covers 4. “Finger safe” contact blocks, 10A rating 5. Function indicating colors per NFPA 79 unless otherwise shown on the drawings 6. Engraved corrosion resistant nameplates 7. LED lamps 8. Mode selector switches shall have 1 spare set auxiliary contacts 9. Indicator lights to be Push-to-Test 10. Potentiometer ratings to match I/O devices connected

2.2 TERMINAL BLOCKS:

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Phoenix Contact 2. Entrelec 3. Weidmuller 4. Allen Bradley 5. Approved Equal


C. Terminal Blocks: 1. Terminal blocks shall be DIN-rail-mounted one-piece molded plastic blocks with

tubular-clamp-screw type, with end barriers, dual side terminal block numbers and terminal group identifiers. Terminal blocks shall be rated for 600 volts except for control and instrumentation circuits, or 4-20 mA analog signal conductors.

2. Provide 600 volt rated terminal blocks for any conductor carrying any voltage over 120 volts to ground.




6. Do not land more than two conductors per terminal point. Use the manufacturer’s provided bridge connectors to interconnect terminal blocks terminating common or ground conductors.


8. Control circuits, 120 volts and below, and 4-20 mA analog signal conductors shall be terminated with manufacturer’s recommended ferrules. Ferrules shall be provided with plastic sleeves.

9. Provide an AC ground bar bonded to the panel enclosure, if metal, with 20 percent spare terminals.


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2.3 WIRE TROUGHS:

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Panduit 2. Taylor 3. Approved Equal


2.4 DIN RAILS:

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Phoenix Contact 2. Entrelec 3. Weidmuller 4. Allen Bradley 5. Approved Equal


2.5 SIGNAL ISOLATORS, BOOSTERS, CONVERTERS

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Phoenix Contact 2. Acromag Inc. 3. Moore Industries 4. Approved Equal

B. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety: 1. Type:

a. Externally powered solid state electronic type/ Loop powered devices are not acceptable.

2. Functional/Performance: a. Accuracy: 0.15 percent b. Inputs: Current, voltage, frequency, temperature, or resistance as required c. Outputs: Current or voltage as required d. Isolation: There shall be complete isolation between input circuitry, output

circuitry, and the power supply e. Adjustments: Zero and span adjustment shall be provided f. Protection: Provide RFI protection g. 24 VDC power input

3. Physical: a. Mounting Suitable for DIN Rail mounting in an enclosure or instrument rack

4. Options/Accessories Required: a. Mounting rack or general purpose enclosure as required.

2.6 POTENTIOMETER / RTD TRANSMITTERS

A. Subject to compliance with the contract documents, the following manufacturers are acceptable:

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1. Phoenix Contact 2. Moore Industries 3. Approved Equal


C. Design and fabrication: 1. Solid state electronics 2. Transmit analog signal directly proportional to measured impedance input. 3. Power source: 24 VDC. 4. Input: 0-1000 ohms. 5. Output signal: 4-20 mA DC. 6. Accuracy (maximum error): ±o.25 percent. 7. Ambient temperature range: 0-140 deg F.

2.7 PANEL DISPLAYS

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Precision Digital 2. Red Lion 3. Moore Industries 4. Approved Equal


C. Design and fabrication: 1. Input: analog 4-20 mA 2. Rating: NEMA 4X, IP65 3. Shallow Depth Case 3.6" Behind Panel 4. Power Supply: 24 VDC or 120 VAC as shown on drawings 5. Optional features to be supplied: Four separate contacts 6. Output: analog 4-20 mA 7. Display: minimum digit height of 1”; sunlight readable

2.8 RELAYS AND TIMERS

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Square D 2. IDEC 3. Potter-Broomfield 4. Allen-Bradley 5. Approved Equal


C. Type: 1. Relays shall be double pole, double throw, octal plug in type with a transparent dust

cover. The relay shall be equipped with an indicating light to indicate when its coil is energized.

2. Units shall be of the general purpose plug-in type.

D. Functional/Performance:

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1. Coil voltage shall match supply voltage. 2. Contact arrangement/function shall be as required to meet the specified control

function. 3. Mechanical life expectancy shall be in excess of 10,000,000 cycles. 4. Duty cycle shall be rated for continuous operation. 5. Units shall be provided with integral indicating light to indicate if relay is energized. 6. Solid state time delays shall be provided with polarity protection (DC units) and

transient protection. 7. Time delay units shall be adjustable and available in ranges from .1 second to 4.5

hours. 8. Plug-in general purpose relay. 9. Blade connector type 10. Contact material: Silver cadmium oxide 11. Relay sockets are DIN rail mounted 12. Internal neon or LED indicator is lit when coil is energized 13. Clear polycarbonate dust cover with clip fastener 14. Operating temperature: -20 to +150 Deg F 15. UL listed or recognized

E. Ratings: 1. For 120VAC service provide contacts rated 10 amps at 120VAC, for 24VDC service

provide contacts rated 5 amps at 28VDC, for electronic (milliamp/ millivolt) switching applicator provide gold plated contacts rated for electronic service.

2. Relays shall be provided with dust and moisture resistant covers.

F. Physical: 1. DIN Rail mounting base 2. Screw Terminals

G. Options/Accessories Required: 1. Provide mounting sockets with pressure type terminal blocks rated 300 volt and 10

amps. 2. Provide mounting rails/holders as required.

2.9 ANALOG SIGNAL SURGE PROTECTIVE DEVICES

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. AGM Electronics 2. Acromag Inc. 3. Moore Industries 4. Phoenix Contact 5. EDCO 6. Approved Equal


C. Type: 1. For devices to be located in control or termination panels, provide DIN Rail mountable

type 2. For devices to be mounted at loop-powered transmitters, provide pipe mountable type

2.10 POWER SUPPLIES

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. PULS Silverline

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2. Phoenix Contact 3. Sola 4. Approved Equal


C. Design and fabrication: 1. Converts 120 VAC input to DC power at required voltage. 2. Sized as required by the load/ Minimum 2.4 A output 3. AC input: 120 VAC +10 percent -13 percent; 47 to 63 HZ 4. Provision for output failure alarm contact 5. DIN rail mountable 6. All power supplies shall be furnished in redundant pairs

2.11 SURGE PROTECTIVE DEVICES (SPD UL 1449 TYPE 3)

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable (Type 3): 1. EDCO SLAC Series 2. Phoenix Contact 3. Brick Wall Model PWOM20 4. Approved Equal


C. Construction of Type 3.SPD 1. Fully Integrated Component Design: All of the SPD’s components and diagnostics

shall be contained within one discrete assembly. SPDs or individual SPD modules that must be ganged together in order to achieve higher surge current ratings or other functionality will not be accepted.

2. Maintenance Free Design: The SPD shall be maintenance free and shall not require any user intervention throughout its life. SPDs containing items such as replaceable modules, replaceable fuses, or replaceable batteries are not acceptable. SPDs requiring any maintenance of any sort such as periodic tightening of connections are not acceptable.

3. Electrical Noise Filter: Each unit shall include a high-performance EMI/RFI noise rejection filter. Noise attenuation for electric line noise shall be up to 50 dB from 10 kHz to 100 MHz using the MIL-STD-220A insertion loss test method.

4. Internal Connections: No plug-in component modules or printed circuit boards shall be used as surge current conductors. All internal components shall be soldered, hardwired with connections utilizing low impedance conductors.

5. Power and ground connections shall be prewired within the protected equipment. 6. Local Monitoring: Visible indication of proper SPD connection and operation shall be

provided. The indicator light shall indicate that the module is fully operable. The status of each SPD module shall be monitored on the front cover of the module.

7. SPD shall be listed in accordance with UL 1449 Third Edition and UL 1283, Electromagnetic Interference Filters.

8. SPD shall be tested with the ANSI/IEEE Category C High exposure waveform (20kV-1.2/50µs, 10kA-8/20µs).

D. Individual Control Panel and Related Equipment Protection (Type 3) Installation 1. Locate the SPD on the load side of the ground and neutral connections. 2. The SPD shall be connected through a disconnect circuit breaker or fuse as shown on

the drawings. The disconnection means shall be located in immediate proximity to the

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SPD. Connection shall be made via bus, conductors, or other connections originating in the SPD and shall be kept as short as possible.

3. All monitoring and diagnostic features shall be visible from the front of the equipment.

2.12 NAMEPLATES

A. Furnish nameplates for each device as indicated in drawings. Nameplates shall be engraved, laminated impact acrylic, matte finish, black lettering on a white background, not less than 1/16-in thick by 1/2-in by 1-1/2-in, Rowmark 322402. Nameplates shall be attached to the back plate with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”. Prior to installing the nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residues has been removed. Epoxy adhesive or foam tape is not acceptable.

2.13 SPARE PARTS

A. Provide the following spare parts for each control panel in the quantities specified: 1. One box replacement fuses, all types and sizes used in supplied equipment. 2. One box of replacement lamps, of each color, for pilot lights supplied 3. One of each color replacement lens caps for pilot lights 4. One can of aerosol touch-up paint.

B. Spare parts shall be boxed or packaged for long term storage. Identify each item with manufacturer’s name, description and part number on the exterior of the package.

PART 3 - EXECUTION

3.1 INSTALLATION

A. All equipment specified herein shall be factory installed, field adjusted, tested and cleaned as an integral part of equipment specified elsewhere in these Specifications.

END OF SECTION

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I&C – INSTRUMENT SUPPORT HARDWARE Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13345 I&C - INSTRUMENT SUPPORT HARDWARE.DOC

SECTION 13345 INSTRUMENTATION AND CONTROLS - INSTRUMENT SUPPORT HARDWARE

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish and install instrumentation mounting and support hardware, as shown on the Drawings and as specified herein.

B. Hardware shall include anchor systems, adhesive anchor systems, metal framing systems, and other instrumentation installation mounting and support systems as specified herein with additional requirements as shown on the Drawings.

1.2 RELATED WORK


B. Section 13310 I&C - Flow Devices

C. Section 13312 I&C - Level Devices

D. Section 13314 I&C - Pressure Devices

E. Section 13318 I&C - Analytical Devices

F. Section 13325 I&C - Control Panels

1.3 SUBMITTALS

A. Submit, in accordance with Division 1, the manufacturers' names and product designation or catalog numbers for each of the types of materials specified and where shown on the Drawings.

B. The submittal information, for anchor systems, shall contain manufacturer's specifications and technical data including; 1. Acceptable base material conditions (i.e. cracked, un-cracked concrete) 2. Acceptable drilling methods 3. Acceptable bore hole conditions (dry, water saturated, water filled, under water) 4. Manufacturer's installation instructions including bore hole cleaning procedures and

adhesive injection. 5. Cure and gel time tables 6. Temperature ranges (storage, installation and in-service).


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. ASTM E 488-96 (2003); Standard Test Method for Strength of Anchors in Concrete

and Masonry Elements, ASTM International 2. ASTM E 1512-93, Standard Test Methods for Testing Bond Performance of Adhesive-

Bonded Anchors, ASTM International 3. AC308; Acceptance Criteria for Post-Installed Anchors in Concrete Elements, Latest

revision 4. SAE 316 Stainless Steel Grades

B. All equipment components and completed assemblies specified in this Section of the Specifications, having a UL standard, shall bear the appropriate label of Underwriters Laboratories.

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A. The manufacturer of these materials shall have produced similar electrical materials and equipment for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

1.6 JOBSITE DELIVERY, STORAGE AND HANDLING

A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner and Engineer upon delivery of the equipment, an approved copy of all such submittals. Delivery of incomplete constructed equipment, onsite factory work, or failed factory tests will not be permitted.

B. Materials shall be handled and stored in accordance with manufacturer's instructions.

C. Adhesive Anchor Systems 1. Deliver materials undamaged in Manufacturer's clearly labeled, unopened containers,

identified with brand, type, and ICC-ES Evaluation Report number. 2. Coordinate delivery of materials with scheduled installation date, minimizing storage

time at job-site. 3. Store materials under cover and protect from weather and damage in compliance with

Manufacturer's requirements, including temperature restrictions. 4. Comply with recommended procedures, precautions or remedies described in material

safety data sheets as applicable. 5. Do not use damaged or expired materials. 6. Storage restrictions (temperature range) and expiration date must be supplied with

product

D. Metal Framing Systems 1. Material shall be new and unused, with no signs of damage from handling.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition.

PART 2 - PRODUCTS

2.1 ANCHORING SYSTEMS

A. Acceptable Manufacturers 1. Subject to compliance with the Contract Documents, the following Manufacturers are

acceptable: a. HILTI Kwik Bolt 3 b. Approved Equal


B. Product Description 1. Torque controlled expansion anchor consisting of anchor body, expansion element

(wedges), washer and nut. Anchor shall be used for anchor sizes less than 3/8 inch. 2. All parts and materials shall be manufactured of 316 stainless steel and conform to

SAE 316 standards. 3. UL 203 Rated.

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2.2 ADHESIVE ANCHORING SYSTEMS


acceptable: a. HILTI HIT-RTZ with HIT-HY 150 MAX b. Approved Equal


B. Product Description 1. Anchor body with helical cone shaped thread on the embedded end and standard

threads on the exposed end, with washer and nut, inserted into Injection adhesive. Anchor shall be used for anchor sizes 3/8 inch and larger.

2. All parts and material shall be manufactured of 316 Stainless Steel and shall conform to SAE 316 standards.

2.3 STRUT SUPPORT SYSTEMS


acceptable: a. Tyco Unistrut b. Cooper B-Line c. Approved Equal


B. Product Description 1. Metal framing system for use in the mounting or support of electrical systems, panels

and enclosures, and including lighting fixture supports, trapeze hangers and conduit supports.

2. Components shall consist of telescoping channels, slotted back-to-back channels, end clamps all threads and conduit clamps.

3. Minimum sizes shall be 13/16” through 3-1/4” 4. Components shall be assembled by means of flat plate fittings, 90 degree angle

fittings, braces, clevis fittings, U-fittings, Z-fittings, Wing-fittings, Post Bases, channel nuts, washers, etc.

5. Field welding of components will not be permitted. 6. Unless otherwise specified or shown on the Drawings, all parts shall be manufactured

of 316 stainless steel and conform to SAE 316 standards. 7. Framing systems for chlorine and ammonia rooms shall be manufactured of structural

fiberglass.

2.4 INSTRUMENT PIPE STANDS


acceptable: a. O’Brien Saddlepak b. Approved Equal


B. Product Description

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1. Floor mount pipe stand for use in the mounting or support of Instrumentation Transmitters.

2. Stand shall consist of a 10 by 10 inch base plate of 1/4 inch steel with a minimum 40 inch long 2 inch steel tube center welded with a minimum of two 8 inch long gussets fully welded for maximum strength. The base plate shall have slotted mounting holes near all four corners.

3. The stand shall be fully zinc metallized or hot dip galvanize coated. 4. Field welding of components will not be permitted.

2.5 INSTRUMENT SUNSHIELD


acceptable: a. O’Brien VIPAK b. Anderson Greenwood c. Approved Equal


B. Product Description 1. Pipe stand or structure mounted sunshield for use in the protection of instrumentation

from direct sunlight. 2. Sunshield shall consist of a minimum 10 inch overhang with a clear view of the

instrument display and working space for service of the instrumentation without removal. The sunshield shall be made of fiberglass reinforced plastic with UV inhibitors unless shown otherwise on the drawings. All mounting hardware shall be manufactured of 316 or 316L Stainless steel.

3. All aluminum or stainless steel Sunshields shall have all edges ground smooth without burs or sharp edges.

2.6 INSTRUMENT TUBING AND FITTINGS


acceptable: a. Tubing

1) Swagelok 2) Parker 3) Approved Equal

b. Fittings 1) Swagelok 2) Parker 3) Approved Equal

c. Valves 1) Whitney 2) Parker 3) Approved Equal


B. Product Description 1. All instrument air header and branch connections shall be 316 stainless steel.

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2. All instrument shut-off valves and associated fittings shall be supplied in accordance with the piping specifications and all instrument installation details. Fittings shall be 316 stainless steel. Valves shall be 316 stainless steel.

3. All instrument tubing shall be fully annealed ASTM A269 Seamless 316 grade free of O.D. scratches and having the following dimensional characteristics as required to fit the specific installation: a. 1/4-in to 1/2-in O.D. x 0.035 wall thickness b. 5/8-in to 1-in O.D. x 0.049 wall thickness c. 1-in O.D. x 0.065 wall thickness d. 1-1/4-in O.D. x 0.065 wall thickness e. 1-1/2-in O.D. x 0.083 wall thickness f. 2-in O.D. x 0.095 wall thickness

4. All process connections to instruments shall be annealed 1/2-in O.D. stainless steel tubing, Type 316.

5. All mounting hardware shall be provided of 316 Stainless steel 6. All tubing shall be supported by stainless steel and installed as per manufacturer's

installation instructions.

PART 3 - EXECUTION

3.1 GENERAL

A. The Contractor shall install all equipment strictly in accordance with the manufacturer's instructions and the Contract Drawings.

B. The location of all devices is shown, in general, on the Drawings and may be varied within reasonable limits so as to avoid any piping or other obstruction without extra cost, subject to the approval of the Owner. Coordinate the installation of the devices for piping and equipment clearance.

C. No instrumentation or electrical equipment shall be attached to or supported from, sheet metal walls.





3.3 POST INSTALLED ANCHOR SYSTEMS

A. Prior to installation of the anchor systems, the hole shall be clean and dry in accordance with the manufacturer’s instructions.

3.4 CLEANING

A. Remove all rubbish and debris from inside and around the installation. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.

END OF SECTION

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I&C – PROCESS CONTROL DESCRIPTIONS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13400 I&C - PROCESS CONTROL DESCRIPTIONS.DOCX

SECTION 13400 INSTRUMENTATION AND CONTROLS – PROCESS CONTROL DESCRIPTIONS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. This specification section describes the process control narratives for the Phase I Biosolids System upgrade at the Flower Mound Water Treatment Plant. The Control Descriptions are not intended to be an exhaustive list of all software components required to execute control strategies. Rather they are a supplement to the drawings, schedules, and other specification sections.

B. Other programming responsibilities are listed in Section 13305 I&C - Application Services (ASP).

C. The Control Descriptions specified herein are performance-based and defines the minimum requirements for the ASP. Coordination of the various programs will be the responsibility of the ASP. See Section 13300 and Section 13305 for additional coordination meeting and workshop requirements.

1.2 RELATED WORK


B. Section 13305 I&C - Application Services

1.3 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of Division 1, Section 13300, and as specified herein.


A. The control loop descriptions provide the functional requirements of the control loops represented in the Contract Documents. Descriptions included are: 1. Control system overview and general description 2. Major equipment to be controlled 3. Major field mounted instruments (does not include local gauges) 4. Manual control functions 5. Automatic control functions/interlocks 6. Major indications provided at local control panels and motor starters / VFD 7. Remote indications and alarms

B. The control loop descriptions are not intended to be an exhaustive listing of all software components and other elements required to execute loop functions, but are rather intended to supplement and complement the drawings and other specification sections. The control loop descriptions shall not be considered equal to a bill of materials.

C. Provide instrumentation hardware and software as necessary to perform control functions specified herein and as shown on drawings.

1.05 SYSTEM CONTROL PANELS

A. List of Control Panels (aka, Programmable Logic Controller (PLC), etc.): 1. Belt Filter Press No.1 (PLC-BFP1) 2. Belt Filter Press No.2 (PLC-BFP2) 3. Lime Stabilization System Control Panel (PLC-SSCP) 4. Gas Alarm Control Panel (GAP)

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B. Programming of both Belt Filter Press Control Panels will be by the Belt Press vendor.

C. Programming of the Lime Stabilization System Control Panel will be by the Lime Stabilization System vendor.

D. Programming configuration of the existing PLC-MSB and Plant graphical user interface modifications shall be performed by the Application Services Provider (ASP). The programming shall incorporate the control descriptions as specified herein. Coordination of the various programs shall be the responsibility of the ASP.


PART 3 - EXECUTION

3.1 CONTROL LOOPS (ALL)

A. General 1. All PLC programming and graphical user interface configuration shall be done in

accordance with the City of Flower Mound established standards and conventions. Where conflicts exist between this specification and established Plant standards and conventions, the ASP shall issue a request for information (RFI) for clarification.

2. All calculations, alarms, and/or shutdown point determinations based on analog values, timer functions, numeric manipulations, etc. shall be accomplished in the PLC and not in the graphical user interface (HMI, OIT, etc.) software.

B. Safety, Monitoring, and Control Features 1. Alarms

a. All open/close valves and motors monitored by the PLC system shall have a maximum time value allowed to either open/close or start/stop. Failure to achieve the control function within this maximum time value will result in a discrepancy alarm for each piece of equipment. An alarm will be calculated in the PLC and shown in the graphical user interface software for indication of the control function failure (e.g. Pump XX-XXXXX-X FAIL TO START, Valve XX-XXXXX-X FAIL TO CLOSE, etc.). These time delay values will be set during startup and are not operator configurable.

b. The integrity of all analog signals will be verified within the PLC. An alarm will be calculated in the PLC and displayed in the graphical user interface for any analog signal that is beyond range or otherwise invalid (high or low). The Operator shall acknowledge, correct the situation, and reset the loop alarm in order for control to revert back to normal. 1) Process Variable Bad Alarm 2) Rate of Change Alarm

c. When the PLC program VFD pump control speed does not match the VFD pump speed feedback, or variable valve position command does not match the position feedback, within tolerance after a certain time delay, an alarm will be calculated in the PLC and displayed in the graphical user interface software for indication of the control function failure. Engineer level security login credentials needed to adjust the tolerance and time delay at the graphical user interface. These values will be initially set during startup by the ASP working with Plant Operations.

d. All analog alarms shall have provisions for Low, Low-Low, High, and High-High alarms.

e. Other specific alarms are designated in the control loop descriptions. f. When this control narrative or existing Plant Standards require that an alarm

condition is to be latched, it shall be latched at the control level where it is

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originated (e.g. alarms that are determined in the PLC are latched in the PLC). All latched alarms can be reset from the graphical user interface.

2. Totalize all pump run times in the PLC and monitor on the graphical user interface. There are to be two run times maintained: a. Cumulative Resettable (from the graphical user interface). b. Cumulative Non-Resettable.

3. "Interlock" is a field status point that is hardwired directly to a local control panel or motor starter. This condition must be satisfied in order for the associated machine to be operated and to remain in operation. This point may be wired in parallel to the PCS for remote monitoring, but the safety control functionality does not require PLC intervention. An example is a High Discharge Pressure that will cause a pump to stop if it is running, and will not allow the pump to start if the condition is preexisting. In specific situations, an interlock may involve peer-to-peer communications between PLCs instead of hardwiring if specifically defined as such.

4. "Permissive" can be either a field status point that is hardwired directly to a local control panel or it can be a logical control point from the PCS. It is a requirement to start a machine, but is not necessary for the machine to continue operation once it is started. An example is a high sump level switch that will start a sump pump, but the sump pump will continue operating even after the high sump level switch is cleared. Typically the sump pump would continue operating until a low sump level switch is used to stop the pump. In this case, the low sump level switch could be considered an "interlock" depending on how it is connected.

5. PLC Diagnostics and Cabinet Alarms are to be incorporated into the graphical user interface following existing Plant conventions and standards. These will include such points as power supply alarms, door intrusion alarms, network communication status, and other alarms as are typical for this Plant.

C. Operator Entry 1. Operator entries require password-protected controlled access to the graphical user

interface. This security system limits the level of access to various functions by individuals. ASP shall maintain the current graphical user interface configuration conventions throughout all new application programming.

2. Entries made by the Operator (such as operation modes, set points, etc.) shall be displayed on the process screens for information.

3. All Operator changes shall be logged by the graphical user interface software and shall include the point that was adjusted, graphical user interface station where the change was made, the Operator that made the change, the date and time of change.

4. The software shall test all Operator entered set points. All such set points are to be between minimum and maximum values. These minimum and maximum values shall be Plant Engineer adjustable via the graphical user interface software.

5. Engineer level security login credentials needed to adjust time delays, alarm tolerances, and PID tuning parameters at the graphical user interface.

D. Control Modes 1. Computer (Remote) Manual: In this mode, all automatic functions associated with a

specific control loop are disabled except for safety interlocks and alarms. Provisions shall be provided to allow Operations staff to access the following functions from the graphical user interface: a. Start/Stop Motors b. Open/Close Valves – All valves that are electrically actuated are to have the

ability to be manually controlled from the Plant SCADA System whether there is any automatic control or not.

c. Adjust Variable Motor Speeds. d. Adjust Modulating Valve Positions.

2. Computer (Remote) Auto: In this mode, all automatic functions associated with a specific control loop are controlled by the PLC automatic logic. Operations staff can

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only adjust the following functions from the graphical user interface (with adequate login credentials): a. Control Mode. b. PID Loop Set points and Tuning Parameters (Level Set points, Timer Values,

etc.). c. Pump Lead/Lag Settings.

3. Local Manual: This mode is available only with those pieces of equipment (motors, valves, etc.) that have an HOA, LOR, or similar switch. In this mode, all remote control (remote manual or remote auto) functions associated with that piece of equipment are disabled, including any PLC-based safety permissive. Operations staff shall set or adjust the following functions from the local control devices (e.g. pushbuttons, hand switches, etc.): a. Start/Stop Motors b. Open/Close Valves c. Adjust Variable Motor Speeds d. Adjust Modulating Valve Positions

4. Motor control programming in the PLC shall incorporate bumpless transfer such that switching the motor controller HOA (or LOR) switch from HAND (or LOCAL) to AUTO (or REMOTE) results in a smooth transition without upset to running status or speed. When the PCS PLC is communicating peer-to-peer with an individual motor controller PLC, incorporate bumpless transfer but include logic to ensure that when communications are lost between the motor controller and the PLC, the motor block reestablishes the existing conditions of the motor controller before it is given remote control. This should alleviate the chance of the motor block accidently shutting down a motor when communications are restored.

3.2 PLANT WATER PUMP STATION

A. General: The plant water pump station will be monitored and/or controlled by the existing PLC-MSB located in the Plant Water Building MCC Room. The plant water pumps will sequence on/off and vary speed to maintain an Operator entered Pressure Set Point.

B. Pressure Meter (PE/PIT-671) and PSH-671 1. General: A new pressure transmitter is being provided on the plant water pump

station discharge header and will be utilized to control the plant water pumps. In addition, a new high discharge pressure switch is being provided. This digital signal is provided to the PLC-MSB for alarming purposes only. When this alarm is set the operator must reset to clear. This alarm provides for notification that the Plant Water System has reached a High Pressure and the Operator should field verify the Plant Water Pumping operation.

2. The plant water pump station discharge pressure value will be made available to be used for pressure control.

3. The graphical user interface will display the pressure indication with provisions to set Low and Low-Low Pressure alarms. Pressure trending will be available for historical reference.

C. Plant Water Pumps (PWP-1 and PWP-2) 1. Each individual pump is controlled by a variable frequency drive. There is also a local

control station (LCS) at each individual pump to remotely Start and E-Stop the pump.

2. Control Modes a. Local Manual Control: There is a Start pushbutton and an E-Stop button located

at the Local Control Station (LCS) for each pump. The start push button becomes operational when the Operator sets the HOA switch at the MCC to the Hand position. The Operator may use the Start/E-Stop push button at the LCP or the Start/Stop push buttons at the MCC to start/stop the pump. The VFD manual speed potentiometer located at the MCC will be utilized to vary the speed of the

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pump. The Operators can also monitor the operational status and alarm conditions of each pump from the graphical user interface.

b. Local Automatic Control: This does not exist for these pumps. c. Remote Manual Control: When the HOA switch is in AUTO, and the Plant Water

System Control Strategy is in MANUAL, the Operators can monitor the pump, send a Start or Stop command to the Pump, and adjust pump speed from the graphical user interface. Refer to P&ID drawing.

d. Remote Automatic Control: When the Pump HOA switch is in AUTO, and the Plant Water System Control Strategy is in AUTOMATIC, the Pumps are started/stopped automatically and the speed of the pumps varied to maintain the Operator discharge pressure set point.

3. Interlocks (Permissive)

a. To protect both of the plant water pumps, there is a Plant Water Low Level Relay Panel (LLRP-PW) that provides for a low level hardwired permissive interlock to each VFD. When the level drops below the LSL-671 float both of the VFDs are hardwired to stop. When the level rises above the LSM-671 float the hardwired permissive interlock is released allowing both plant water pumps to operate.

b. The Low Level permissive signal is also monitored at the plant graphical user interface.

3.3 BELT FILTER PRESS SYSTEM

A. General: Two new Belt Filter Press units are being provided with all ancillary items. These units are to be located within the Dewatering Building. Control Panels for each unit will be provided in the Control Room and remote control panels are to be provided adjacent to each of the Belt Filter Presses. These Press units are specifically designed for the separate of solids from municipal wastewater sludge. Prior to delivery of the sludge to the press polymer will be mixed with the sludge to condition the sludge for optimum dewatering.

B. The Belt Filter Press System consists of the following equipment: 1. Structural Main Frame 2. Gravity Drainage Section 3. Pressure Section 4. Belt Wash System 5. Belt Alignment System 6. Belt Tensioning and Alignment Drive System 7. Belt Drive 8. Dewatering Belts 9. Electrical Control Panel (PLC-BFP*) 10. Remote Control Panel (LCP-BFP*)

C. The Belt Filter Press System is a vendor supplied system and is controlled by a Programmable Logic Controller (PLC). The PLC will be programmed by the vendor.

D. The PLC will be connected to the SCADA control system via existing Ethernet communication copper cables. The SCADA control system will be configured to monitor the Belt Filter Press units as follows: 1. Run status of all equipment 2. Machine E-stop 3. Belt Limit Alarm 4. Belt VFD Failure 5. Loss of Cake Alarm 6. Air Loss Alarm 7. Belt Press HOA (Local or Remote Status) 8. Pre-Wet Alarm 9. Polymer Pump Failure Alarm

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10. Sludge Pump Failure Alarm 11. Low Water Pressure Alarm 12. Sludge Conveyor Fail Alarm 13. Wash Down Status 14. Belt Speed Indicator 15. Sludge Flow Indicator 16. Polymer Flow Indicator 17. Provide the capability for the SCADA Control System to monitor an additional 15


18. Provide the capability for the SCADA Control System to monitor an additional 5 analog signals. These analog signals will be further defined during the ASP graphics workshops. Reference specification section 13305.

3.4 LIME STABILIZATION SYSTEM

A. General: The Lime Stabilization System receives, stores and conveys granular quicklime that will be mixed with the sludge-cake produced by two Belt Filter Presses. The end product will be Class B cake delivered to two dumpster/veyor transport bins. The transport bins are utilized to transport the Class B sludge-cake off site.

B. The Lime Stabilization system consists of the following equipment: 1. Bulk Lime Storage Silo with the following:

a. Silo bottom cone mounting ring b. Bin activator c. 8-inch control valve d. Bin Level indicators (3)

2. Lime Feed Screw Conveyor 3. Sludge/Lime Mixer that produces Class B end product 4. Discharge Belt Conveyor

a. Two belt plows 5. Stabilization System Control Panel (SSCP) 6. Heat System Power Control Center (HSPCC)

C. The Lime Stabilization System is a vendor supplied system and is controlled by a Programmable Logic Controller (PLC). The PLC will be programmed by the vendor.

D. The PLC will be connected to the SCADA control system via Ethernet fiber optic communication cables. The SCADA control system will be configured to monitor the SSCP as follows: 1. Run status of all equipment including existing Lime Storage Silo equipment 2. Failure status of all equipment including existing Lime Storage Silo equipment 3. Operating Mode of SSCP System 4. Lime Storage Silo High Level 5. Lime Storage Silo Reorder Level 6. Lime Storage Silo Low Level 7. Provide the capability for the SCADA Control System to monitor an additional 15


8. Provide the capability for the SCADA Control System to monitor an additional 5 analog signals. These analog signals will be further defined during the ASP graphics workshops. Reference specification section 13305.

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3.5 MULTI-CHANNEL GAS ALARM MONITORING SYSTEM

A. General: The Gas Alarm monitoring system will provide alarming and monitoring of the Hydrogen Sulfide and Methane gas sensors which are located within the Belt Filter Press room.

B. The multi-channel controller will provide simultaneous display, beacon and horn notification and alarming functions to the SCADA control system. In addition, the controller will provide a dry contact to the HVAC control panel to provide an override signal that initiates operation the supply and exhaust fans.

C. The multi-channel controller provides dry contacts to PLC-MSB for alarming at the SCADA control system. These alarms are as follows: 1. North Belt Filter Press Room High Hydrogen Sulfide alarm 2. South Belt Filter Press Room High Hydrogen Sulfide alarm 3. North Belt Filter Press Room High Methane alarm. 4. South Belt Filter Press Room High Methane alarm.

3.6 POLYMER FEED SYSTEM

A. General: The polymer feed system will automatically dilute, blend, and feed liquid polymer solution of commercial grade neat polymer to the Belt Filter Press. The Polymer System will consist of a Multi-Zone Mixing Chamber, a dilution water assembly, polymer metering pump, solution discharge assembly and a control panel that is integral to the system frame.

B. The polymer feed rate will be manually adjusted by the operator at either the Belt Filter Press control panel or the remote control panel located adjacent to the press.

C. The SCADA control system will monitor, via Ethernet communication, the following Polymer System signals through the Belt Filter Press Control Panel: 1. Polymer System in Remote 2. Polymer System Running 3. Polymer System Failure Alarm 4. Polymer System Flow Indication

END OF SECTION

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I&C – FIELD INSTRUMENT LIST Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13410 I&C - FIELD INSTRUMENT LIST.DOC

SECTION 13410 INSTRUMENTATION AND CONTROLS - FIELD INSTRUMENT LIST

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. This section includes a summary of the process instrumentation list.

1.2 RELATED WORK

A. Refer to Section 13300 I&C - General Provisions.

B. Refer to Section 13400 I&C - Process Control Descriptions.

1.3 SUBMITTALS

A. Refer to Section 13305 I&C - Application Services

B. Refer to Section 13300 I&C - General Provisions.


A. The process instrumentation list provides a summary of the major process instrumentation requirements as utilized within the control loops represented in the Contract Documents. Additional process instrumentation shall be provided as required to fully implement the strategies as described in these specifications and as recommended by the process and mechanical equipment division suppliers.

B. The process instrumentation list is not intended to be an inclusive listing of all elements and appurtenances required to execute loop functions, but are rather intended to supplement and complement the drawings and other specification sections. The input output list shall not be considered an equal to a bill of materials.

C. Provide instrumentation hardware and software as necessary to perform control functions specified herein and as shown on drawings.

1.5 PROCESS INSTRUMEATION LISTING

A. The new process instrumentation list shall be as follows:

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ITEM NO. P&ID TAG DESCRIPTION INSTRUMENT

TYPE SPEC RANGE COMMENTS

1 I-004 FE/FIT-801 Belt Filter Press No.1 Sludge Feed Flow

Magnetic Flow Metering 13310 0 – 300

GPM

6-Inch, Remote Mounted

Transmitter

2 I-004 FE/FIT-802 Belt Filter Press No.2 Sludge Feed Flow

Magnetic Flow Metering 13310 0 – 300

GPM

6-Inch, Remote Mounted

Transmitter

3 I-005 AE/AIT-801 Belt Filter Press Room Hydrogen Sulfide Level (North)

Hydrogen Sulfide Gas Detector

13318 0 – 50 ppm

Hydrogen Sulfide

H2S

4 I-005 AE/AIT-803 Belt Filter Press Room Hydrogen Sulfide Level (South)

Hydrogen Sulfide Gas Detector

13318 0 – 50 ppm

Hydrogen Sulfide

H2S

5 I-005 AE/AIT-802 Belt Filter Press Room Methane Level (North)

Combustible Gas Detector 13318

0 – 99% LEL

Methane (CH4)

6 I-005 AE/AIT-804 Belt Filter Press Room Methane Level (South)

Combustible Gas Detector 13318

0 – 99% LEL

Methane (CH4)

7 I-005 AT-800 Gas Monitoring System

Multichannel Gas Monitoring system

13318

Reference

Detectors

8 I-009 PE/PIT-671 Plant Water Pump Station Discharge Pressure

Differential Pressure Transmitter

13314 0 – 200 PSI With Manifold

9 I-009 PSH-671 Plant Water Pump Station High Discharge Pressure

Pressure Switch 13314

Set @ 100 PSI Rising

10 I-009 LSL-671 Plant Water Pump Station Low-Low Level Lockout Float Switch 13312

Set @ 48-inch

from top of

concrete fill

11 I-009 LSM-671 Plant Water Pump Station Low-Low- Level Reset Float Switch 13312

Set @ 6 Ft from top of

concrete fill

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PART 3 - EXECUTION

3.1 INSTALLATION

A. All Process Instruments listed shall be supplied as specified herein and shall be installed, field adjusted and tested as an integral part of the overall control systems specified elsewhere in these Specifications.

END OF SECTION

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I&C – COMMUNICATIONS INTERFACE EQUIPMENT Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\INSTRUMENTATION AND CONTROL\!WORKING\SECTION 13515 I&C - COMMUNICATIONS INTERFACE EQUIPMENT.DOC

SECTION 13515 INSTRUMENTATION AND CONTROLS - COMMUNICATIONS INTERFACE EQUIPMENT

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. This section of the specifications describes the requirements for communications interface equipment to be furnished as shown in the Drawings.

B. All equipment described herein shall be submitted and furnished as an integral part of assemblies specified in Division 13 Instrumentation and Controls sections.

1.2 RELATED WORK


B. Section 13325 I&C - Control Panels

1.3 SUBMITTALS

A. Reference Section 13300.

B. Submittals for equipment specified herein shall be made as a part of equipment furnished under other sections. Individual submittals for equipment specified herein will not be accepted and will be returned un-reviewed.

C. Submit catalog data for all items supplied from this specification Section as applicable. Submittal shall include catalog data, functions, ratings, inputs, outputs, displays, etc., sufficient to confirm that the equipment provides every specified requirement. Any options or exceptions shall be clearly indicated and located in the beginning of the submittal package.


A. Instrumentation equipment, materials and installation shall comply with the National Electrical Code (NEC and with the latest edition of the following codes and standards: 1. NEMA ICS 1-101 Diagrams, Designations and Symbols 2. Underwriters Laboratories (UL) 3. UL 508, the Standard of Safety for Industrial Control Equipment

B. All equipment and installations shall conform to applicable federal, state, and local codes.

C. All equipment shall comply with the requirements of the National Electric Code and Underwriters Laboratories (UL) where applicable.

D. Each specified device shall also conform to the standards and codes listed in the individual device paragraphs.


A. The manufacturer of this equipment shall have produced similar equipment for a minimum period of five (5) years. When requested by the OWNER/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.



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1.6 WARRANTY

A. The Contractor shall warrant the equipment to be free from defects in material and workmanship for two (2) years from date of acceptance of the equipment containing the items specified in this Section. Within such period of warranty the General Contractor (GC) shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the GC at no expense to the OWNER.

PART 2 - PRODUCTS

2.1 MODULAR INDUSTRIAL ETHERNET SWITCH LAYER 3 (PLC CONTROL PANELS)

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Hirschmann 2. Cisco 3. Moxa 4. Approved Equal


C. Environmental 1. Operating temperature: -40° F to 167° F 2. Operating humidity: 10 – 95% non-condensing 3. Storage temperature: -13 to 185° F 4. Electrical classification: intrinsically safe for UL 1602 Class I Division 2 A-D locations

D. Physical 1. Enclosure: NEMA TS-2. 2. Fully modular construction 3. Power supply: 120 VAC from UPS source 4. Microprocessor-based managed type. 5. DIN rail mountable capability.

E. Functional Performance 1. Per port status LED indication 2. Port based Ethernet MAC security individually port configurable 3. Wire speed switching, 16 Gigabit switching fabric 4. HSRP protocol support 5. Cisco Express Forwarding Hardware Routing Architecture 6. SNMPv1, SNMPv2c, and SNMPv3 Support 7. 802.1d Spanning Tree Protocol Support 8. HTTPS accessible 9. Common Industrial Protocol (CIP) Management Objects Support 10. Smart Templates for EtherNet/IP 11. PROFINET v2 certification 12. Alarm contacts for external fault notification 13. 10/100 BaseT ports with RJ-45 connectors for Category 6 cabling 14. Switch configuration on removable/ configurable via Flash Memory module 15. LC type fiber optic connectors for 100BaseFX, 1000BaseSX for multimode fiber and

1000BaseLX for single mode fiber as shown on the drawings 16. Fully managed switch capability 17. PoE ports where required.

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F. Options and accessories required: 1. Provide maximum installation space for additional future modules for each switch

location. 2. Provide twenty (20) percent spare port capacity for each port type.

G. Spare Assemblies 1. Provide 1 spare module of each type used

2.2 INDUSTRIAL SERIAL TO ETHERNET/ PROTOCOL CONVERTER

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Digi One IAP Series 2. Moxa MGate 5105-MB-EIP Series 3. Approved Equal


C. Environmental 1. Operating temperature: 32° F to 104° F 2. Operating humidity: 20 – 95% non-condensing 3. Storage temperature: -40 to 158° F

D. Physical 1. Power supply: 24 VDC 2. Microprocessor based managed type. 3. DIN rail mountable. 4. Class 1 Division 2 rated

E. Functional Performance 1. Per port status LED indication 2. Wire speed switching. 3. 10/100BaseT ports with RJ-45 connectors for Category 6 cabling. 4. ST or SC type fiber optic connectors for 100BaseFX, 1000BaseSX for multimode fiber

and 1000BaseLX for single mode fiber as shown on the drawings 5. RS-485 ports with terminals. Selectable link termination (100 ~120 Ohms)

F. Options and Accessories Required: 1. The protocol interface shall implement the following:

a. Transfer of basic I/O data via User Datagram Protocol (UDP)-based implicit messaging

b. Uploading and downloading of parameters, set points, programs and recipes via TCP (i.e., explicit messaging.)

c. Polled, cyclic and change-of-state monitoring via UDP, such as RPI and COS in Allen Bradley's ControlLogix control systems

d. One-to-one (unicast), one-to-many (multicast), and one-to-all (broadcast) communication via TCP

e. Use of well-known TCP port number 44818 for explicit messaging and UDP port number 2222 for implicit messaging

2. The media protocol converter shall meet the following criteria: a. The converter shall support 10/100Base-T Ethernet. The serial port speed (baud

rate) shall support 230 kbps. The protocol shall support Modbus TCP, EtherNet/IP, DF1, and Modbus RTU/ASCII. Protocol shall be Web Browser configurable.

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2.3 ETHERNET COMMUNICATION CABLES

A. Subject to compliance with the contract documents, the following manufacturers are acceptable: 1. Belden 2. Approved Equal


C. Cables for Ethernet: Category 5e Above Grade Cable: Sunlight and Oil Resistant U/UTP 003 Cable, non-plenum. 1. Conductors: 4 bonded pair 24 AWG Bare Copper 2. Insulation: Polyolefin 3. Jacket: PVC with 600 volt rated color of jacket to match color code as follows.

a. Green: Primary SCADA b. Yellow: Secondary SCADA c. Blue: Corporate Network, including VOIP Phones d. White: Security System e. Red: Fire Alarm-Related

4. Transmission Standards: ANSI/TIA568C 5. Nominal Velocity of Propagation: 69% 6. Flame Test Method: CMR Regulatory Compliance 7. Manufacturers: Belden 7957A

D. Cables for Ethernet: Category 6 Above Grade Cable: Sunlight and Oil Resistant U/UTP 003 Cable, non-plenum. 1. Conductors: 4 bonded pair 23 AWG Bare Copper 2. Insulation: Polyolefin 3. Overall Cabling Separator Material of Foamed Polyolefin Tape 4. Jacket: PVC with 300 volt rated Color of jacket to match color code.

a. Green: Primary SCADA b. Yellow: Secondary SCADA c. Blue: Corporate Network, including VOIP Phones d. White: Security System e. Red: Fire Alarm-Related

5. Transmission Standards: Category 6 - TIA 568.C.2 6. Nominal Velocity of Propagation: 72 % 7. Flame Test Method: UL1666 Vertical Riser 8. Manufacturers: Belden 7940A

E. Cables for Ethernet: Category 5e Below Grade Outdoor and Under grade locations Cable: Sunlight and Oil Resistant Category 5e U/UTP 003 Cable, non-plenum. 1. Conductors: 4 pair 24AWG Bare Copper 2. Insulation: Polyolefin 3. Shield: 100 percent aluminum foil polyester tape with drain wire 4. Jacket: LLPE (Linear Low Density Polyethylene) with 300 volt rated and

manufacturer’s identification 5. Misc.: NEMA WC-63.1, listed for outdoor and wet locations use 6. Manufacturers: Belden 7937A

2.4 SPARE PARTS

A. Provide the following spare parts for each communication panel in the quantities specified: 1. One box replacement fuses, all types and sizes used. 2. One replacement port interface and patch cable of each type used.

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PART 3 - EXECUTION

3.1 INSTALLATION

A. All equipment specified herein shall be factory installed in an overall assembly, field adjusted, tested and cleaned as an integral part of equipment specified elsewhere in these Specifications.

B. The Application Services Provider (ASP) shall be responsible for configuration, programming, and documentation of all networks switches. A hard and soft copy of the configurations of each of the switches, with their IP addresses, shall be included in the final documentation package. The Network Manager software shall also be configured to provide backups and monitoring of the switch configurations. IP addresses will be provided by the Owner’s personnel.

C. The ASP shall test the complete network connection prior to installation of the PLC equipment. Ethernet testing shall be accomplished by using either dedicated network test equipment or demonstration of the network using laptop computer with network testing software.

3.2 FIBER OPTIC TERMINATION AND CROSS-CONNECTS

A. Fiber optic termination hardware shall be installed according to industry standards and specifications and the manufacturer’s recommendations as shown on the Drawings. Note that fiber optic terminations are marked as “Reserved” for future or concurrent contracts. The GC shall terminate all fiber as shown; the intent of the “Reserved” designation is to denote fiber optic data paths. Fiber slack shall be neatly coiled within the fiber termination panel. No slack loops shall be allowed external to the fiber panels. Each cable shall be individually attached to the respective termination panel by mechanical means. The cables strength members shall be securely attached to the cable strain relief bracket in the panel. Each fiber cable shall be stripped upon entering the termination panel and the individual fibers routed in the termination panel. Each cable shall be clearly labeled at the entrance to the termination panel. Cables labeled within the bundle shall not be acceptable. Dust caps shall be installed on the connectors and couplings at all times unless physically connected.

B. The Fiber Optic Strands shall be cross-connected from panel to panel utilizing SC/SC fiber patch cords, 1-Meter in length. The GC shall follow the fiber optic color code. The network switches shall be connected to the fiber panels utilizing SC/SC fiber patch cords, 2-Meters in length.

END OF SECTION

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CONTAINER HANDLING SYSTEM F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 14\14952-CONTAINER HANDLING SYSTEM.DOCX

SECTION 14952 CONTAINER HANDLING SYSTEM

PART 1 - GENERAL



1.2 SUMMARY

A. Furnish, install, start-up, and test two (2) complete container handling systems (DV-1 and DV-2), complete and operable with all necessary controls and connections as shown on drawings.

B. Related Sections: 1. Division 16 Section 16150 “NEMA Frame Induction Motors, 600 Volts and Below”

1.3 SUBMITTALS

A. Submittals shall be prepared and submitted in accordance with Division 1 Section.


A. Qualifications 1. The equipment manufacturer shall furnish a qualified field representative to inspect all

equipment described herein after installation, to assist in troubleshooting, to advise CONTRACTOR and OWNER during start-up and testing, and to instruct OWNER's personnel in routine maintenance and troubleshooting procedures. The CONTRACTOR shall coordinate the scheduling of such training and start-up maintenance with OWNER's personnel.

2. Manufacturer's installation report is required prior to final acceptance. Startup and testing shall be performed on permanent power supply only, in accordance with the manufacturer's recommendations.

3. All pieces of equipment shall have a stainless steel manufacturer's nameplate securely affixed in a conspicuous place on the equipment showing the serial number, model number, manufacturer and other pertinent nameplate data.

4. Manufacturer shall maintain a complete stock of spare parts commonly needed for the equipment specified at a location within the State of Texas, or be capable of responding by overnight shipment of spare parts from the manufacturer.



1.6 WARRANTY

A. Special Equipment Warranty. 1. The equipment manufacturers shall jointly warrant to the OWNER and to the

CONTRACTOR that all equipment, including all components of the complete assembly furnished by it hereunder, complies in all respects with the design and specifications of these Documents and contains no defects of material or workmanship.

2. In the event of failure of any part or parts of the equipment during the warranty period due to defects of design, materials, or workmanship; the CONTRACTOR shall replaced affected part or parts shall be replaced promptly upon notification by the OWNER. All replacement parts shall be furnished, delivered, and installed at the expense of the equipment manufacturer.

3. The warranty period shall be interpreted as the 24-month period following final acceptance of the installed equipment by the OWNER, whichever comes first, and shall be exclusive of the time of use of the equipment in installation, testing, adjusting,

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etc., during the construction period, or of the time in storage, after delivery and prior to installation. Provisional acceptance of the equipment shall not affect the determination of the first year of service. All equipment shall be operated for a minimum 30-day start-up period before final acceptance and before the start of the 24-month warranty period.

4. If the equipment does not meet the requirements of the Specifications, the equipment manufacturer shall correct or service the equipment at no additional cost to meet the specified requirements, where any such deficiencies are the responsibility of the equipment manufacturer. In the event the equipment is unable to meet the specified requirements within the warranty period, the equipment manufacturer shall refund an amount equal to the purchase price of new equipment, which will meet the specific requirements. The amount of the refund shall not exceed the purchase price of the equipment to be replaced.


6. Payment for equipment as "Materials-On-Hand" will not be made until the OWNER receives an approved Special Equipment Warranty.

PART 2 - PRODUCTS

2.1 GENERAL

A. The container handling system is designed to provide the operator a means to evenly distribute material into a roll-off container being deposited from a discharge point or conveyor. Each system has a rated capacity of 20 tons.

B. The components of each container handling system include two (2) runs of runway track with anchors, two (2) drive tracks, one (1) idler articulating carrier, one (1) drive articulating carrier, one (1) positive control dual directional closed loop chain drive system with controls, one (1) return sheave, and the means for automatically filling each dumpster evenly. Two systems shall be provided, as shown on the plans.

C. The container handling system shall be manufactured by D. R. Cordell & Associates, Inc.

2.2 CONTROL PANEL

A. The container handling system manufacturer shall design, furnish and shop test a pedestal mounted control station for each system, for control of system movement. Controls shall include a 3 phase power circuit controlled by a single phase control circuit with step down transformer. The control system shall be designed to handle the expected duty cycle of the container handling system. Power supply is 460 volts 3 phase 60 hertz, and the control circuit will be 120 volts 1 phase 60 hertz.

B. Control schematic shall include a circuit designed to set the motor brake for stopping purposes then open the motor brake for extended periods of time using a programmable controller. Other control features to be included are travel limit switches, torque limiter, warning horn, power on light, hand-off-auto switch with manual forward and reverse pushbuttons, and a manual forward and reverse pushbutton station located in the Belt Filter Press room capable of overriding automatic filling system.

C. All controls are to be located in a NEMA 4X enclosure depending on site conditions. Heaters shall be included in control enclosures. Push buttons for control of the system movement shall be mounted in the enclosure door with indicating lights for "power on", "power off". Enclosure shall be pedestal mounted or wall mounted. The enclosure shall be located as indicated on the contract drawings.

D. The warning horn shall sound for 15 seconds prior to the system moving and shall be activated by the forward and reverse buttons. The warning light shall flash during horn signal and stay flashing during system movement. Light and horn shall be mounted on a post

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secured to the drive winch base. The light shall be easily visible from any vantage point in the room.

E. Automatic filling feature shall be designed to automatically fill the container evenly and shall include all hardware, software, and programming necessary to allow automatic filling and movement of the container. 1. Elevation sensors positioned around the discharge chute shall detect piles created

inside the container. Container movement shall be automatically activated once sensors detect the pile at a predetermined height above the container wall. Once activated, the containers shall automatically move for a timed distance. Prior to movement the horn and light shall sound.

2. Container sensors shall be provided in the loadout area to detect the presence of a container. Automatic filling shall not commence until a container is detected in the starting position and shall terminate upon activation of the container sensor at the ending position.

3. Movement shall only occur if the container sensors are providing the necessary feedback indicating the presence of a container.

4. Elevation and container sensors shall be mounted directly adjacent to the loadout area and shall be field adjustable in all directions.

F. The Control Panel shall interface with the Lime Stabilization System Control Panel via hardwired (dry-contract) signals as shown on the contract drawings: 1. In-Place Ready 2. Bin Full 3. Fault

2.3 RUNWAY AND DRIVE TRACKS

A. The runway track for each container handling system shall be manufactured using 304 stainless steel and be a built up fabricated section, providing a track system on which the drive and idler carts operate. Tracks shall be positioned under a discharge point so that the track extends in either direction from the discharge point as shown on the drawings. Track length shall be as indicated on the drawings spaced at approximately 7’-6".

B. Track joints are spliced with pin connectors 1/4" diameter. Ends of adjoining tracks are drilled to receive three (3) 3/8" diameter pins. Pins are carbon steel or stainless steel to match the type of track being installed. Track ends are shop fabricated to permit smooth transition from track section to track section during carrier travel. No field welding of track joints is required.

C. The chain drive track shall be manufactured using 304 stainless steel base plate and a UHMW guide channel mounted to the base plate. The base plate is drilled at regular intervals for mounting to a constant-slope concrete surface using an expandable anchoring system or the epoxy anchoring system. Two tracks running from the drive winch to the idler sheave are required spaced at approximately 9" apart. The drive chain rides in the guide channel.

D. End stops shall be provided at each end of the four tracks. End stops and track material shall be the same. End stops are shop welded in place at extreme ends of track.

2.4 IDLER ARTICULATING CARRIERS

A. One (1) low profile, heavy duty 304 stainless steel idler carrier having a capacity of 10 tons and a nominal plan size of 8’-3” by 2’-8”, shall be provided for each container handling system. Each idler shall be assembled to prevent skewing and racking and to accurately accept the articulating wheel assemblies.

B. The carriers shall be drilled to ensure articulating axle alignment. The axles shall be held in place by retainer plates which are easily removable to allow component inspection. Dual container wheel stops shall be provided on carrier surface to prevent wheel overload and container roll-off when traveling. Stops shall be factory welded and located to clear any obstruction on the underside of the container.

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C. Each carrier shall be equipped with eight (8) double flanged 304 stainless steel wheels assembled into articulating trolley assemblies. Articulating trolley assemblies are designed to maintain equal wheel loading at all times during carrier travel. Wheels shall interface with the runway track to allow easy tracking and eliminate binding during travel.

2.5 DRIVE ARTICULATING CARRIER

A. One (1) low profile, heavy duty steel drive carrier having a capacity of 10 tons and a nominal plan size or 8’-3” by 2’-8” shall be provided for each container handling system. The unit shall be assembled to prevent skewing and racking and to accurately accept the articulating wheel assemblies.

B. The carriers shall be drilled to ensure articulating axle alignment. The axles shall be held in place by retainer plates which are easily removable to allow component inspection. Dual wheel stops shall be provided to prevent wheel overload and container roll-off when traveling. Stops shall be factory welded and located to clear any obstructions on the underside of the container.

C. The center portion of the drive carrier shall be designed and constructed to allow double articulation, allowing the drive carrier to follow minor irregularities in the track elevation. Drive carrier shall be factory aligned. Center portion of the drive carrier shall be equipped with steel welded lugs for connection of drive chain and swiveling clevis connectors.

D. The drive carrier shall be equipped with eight (8) double flanged 304 stainless steel wheels assembled into articulating trolley assemblies. Articulating trolley assemblies are designed to maintain equal wheel loading at all times during carrier travel. Wheels shall interface with the runway track to allow easy tracking and eliminate binding during travel.

2.6 ARTICULATING TROLLEY ASSEMBLIES

A. Each articulating trolley assembly shall consist of a 304 stainless steel top pivoting shaft, two (2) 304 stainless steel heavy duty side plates, two (2) 304 stainless steel double flanged wheels with stainless steel sealed roller bearings and two (2) 304 stainless steel wheel axles. The top pivoting shaft shall secure the assembly in place on the carrier frame and allow articulating motion for equal wheel loading.

B. Wheels shall be double flanged, 5" tread diameter for operation on 1-1/2" bar track with sealed roller bearings. Wheels to be manufactured from 304 stainless steel. Wheels are to be mounted on the free floating axles and mounted in the heavy duty side plates. All components are easily removable for inspection and replacement if required.

2.7 CLOSED LOOP WINCH

A. A single speed, base mounted, positive control, dual directional electric motor driven carrier drive shall be furnished with the drive carrier. The puller shall operate at a speed to move the container at approximately 18 FPM unless otherwise indicated.

B. The drive base frame shall be a fabricated steel weldment designed for easy access to motor, gearbox and drive wheel.

C. The gearbox shall be cycloidal type design providing high reduction with minimal space requirements. Cycloidal drive shall be Sumitomo, operating in oil bath lubrication. All bearing shall be rated for 5000 hours, L-10 bearing life.

D. A zinc plated steel chain seated in a type 316 stainless steel pocket wheel mounted to the output shaft on the cycloidal gearbox shall connect to the idler sheave also having a sheave 316 stainless steel pocket wheel. The drive sheave and idler sheave shall be mounted in the horizontal plane for a low profile configuration. Drive chain shall run in UHMW guide channel described previously in this specification.

E. The electric motor shall be TENV 30 min. duty rating, 2 HP, single speed with high starting torque characteristics. Motor shall be C-face mounted design with minimum class B insulation. Motor shall operate on 460 volts 3 phase 60 hertz control voltage to be reduced to 120 volt single phase. The motor shall be provided with a 100% torque rated disc type brake, electrically opened and mechanically closed for fail-safe operation. The motor also shall

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include an overload torque limiter to prevent overloading system components. The torque limiter shall electrically interrupt the motor directional circuit in the event of an overload condition.

F. Two magnetically operated travel limit switches shall be provided to stop carrier movement at extreme ends of the track. Steel lugs are secured to the drive chain and positioned on the chain to stop the container at the ends of the drive track. The lugs are field adjustable and can be relocated at a later date if required. The steel lug is detected by the magnetically operated normally closed switch, which opens the directional circuit on the drive winch.

2.8 RETURN SHEAVE

A. The return idler sheave shall be mounted horizontally inside a heavy duty 304 stainless steel weldment designed for low profile and able to withstand truck traffic. Idler sheave is a stainless steel pocket wheel operating on sealed roller bearings. The heavy duty steel housing includes holes for mounting the unit to a concrete floor or pad.

2.9 PAINTING

A. All painting shall be in accordance with Division 9.

B. Stainless steel surfaces shall not be painted including stainless steel runway tracks. Tread surfaces will be taped before painting. All other items will be primer and safety yellow. Standard paint is epoxy paint system.

C. Equipment shall be touch painted in the field after installation. All marks and abrasions shall be primed if required and finish coated with epoxy safety yellow.

2.10 MANUFACTURERS

A. The acceptable equipment shall be Dumpster-Veyor as manufactured by Cordell & Associates, Inc. of Chalfont, Pennsylvania. The Cordell & Associates, Inc. representative for this area is HRM Environmental, 3825 Hillwood Drive, Bedford, Texas 76021, Telephone No. (817)835-0100.

B. The OWNER has received a not-to-exceed quote for the equipment described herein from the representative in the amount of (to be added by addendum). The quote is attached to the end of the specification. In case of any conflicts between the OWNER’s conditions and the Equipment Manufacturers terms and conditions, the OWNER’s conditions shall supersede the Equipment Manufacturer’s.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Installation shall be in accordance with the manufacturer's recommendations and performed by qualified persons. Tracks shall be anchored to the concrete floor or pad with 818 stainless steel threaded rod and Epcon Epoxy System or 316 stainless steel expansion anchors depending on surface conditions.

B. The epoxy mounting system incorporates a leveling nut under track to set elevation of track along the length. After installation, grout shall be installed under track along the entire length. Drive winch and idler sheave shall be installed the same way if the epoxy system is used.

C. Track, guide channel, drive and idler shall be installed at the same elevation (±) 1/4". Care should be taken to ensure alignment of guide track to drive chain during installation.

3.2 TESTING AND STARTUP

A. The container handling system shall be tested for proper operation prior to being put into service. All controls, lights, horns, limit switches and stops shall be tested in a no-load situation.

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B. A container provided by others can be used to perform a partial-load test. The container, delivery of the container and removal of the container is to be provided by the Owner. An operational and partial load test will be performed with an empty container. The Owner is responsible for obtaining a loaded container to perform a full-load test.

C. Tests shall include operating the equipment the full length of the tracks, checking travel limit switches and carrier operation.

END OF SECTION


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BASIC MECHANICAL REQUIREMENTS F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15010 BASIC MECHANICAL REQUIREMENTS.DOC

SECTION 15010 BASIC MECHANICAL REQUIREMENTS

PART 1 - GENERAL



1.2 SUMMARY

A. The applicable provisions of this Section shall apply to the following: 1. Division 11 – Equipment, all sections. 2. Division 13 – Special Construction, equipment and special construction sections. 3. Division 15 – Mechanical, all sections.

B. Drawings are diagrammatic only and do not provide fully all dimensioned locations of various elements of work. Determine exact locations from field measurements.

C. Where the work “concealed” is used in connection with insulating, painting, piping, ducts and the like, the work is understood to mean hidden from sight as in chases, furred spaces, or suspended ceilings. “Exposed” is understood to mean open to view.


A. Materials specified by reference to standards of ASTM, ANSI, AWWA, ASME, TxDOT, Federal, or other standard organizations must comply with latest edition (except where specified otherwise in individual sections by noting year or edition) in effect on date bids are received.

B. Requirements in referenced standards established minimum requirements for all equipment, materials, and work. For instances where capacities, size, or other feature of the equipment, devices, or materials exceed these minimums, meet the listed or requirements specified in the Drawings and Specifications.

1.4 CODE REQUIREMENTS AND PERMITS

A. Perform work in accordance with applicable statutes, ordinances, codes, and regulations of governmental authorities having jurisdiction.

B. Resolve code violations discovered in Contract Documents with ENGINEER prior to award of Contract. After award of Contract, CONTRACTOR shall make any correction or addition necessary for compliance with applicable codes at no additional cost to OWNER.

C. CONTRACTOR shall obtain and pay for all permits and licenses, pay all fees, and obtain all certificates of inspection and other permits required to place Work in operation.

1.5 OPERATION AND MAINTENANCE

A. Provide required copies of operation and maintenance data when designated in the individual sections in accordance with Section 01782 “Operation and Maintenance Data.”

B. Provide the services of qualified manufacturers’ representatives when designated in the individual sections in accordance with Section 01640 “Manufacturers’ Services.”

1.6 FACILTY STARTUP, DEMONSTRATION, AND TRAINING

A. Provide services of manufacturers’ representatives, as well as qualified personnel, when designated in the individual sections for equipment and system testing and facility startup in accordance with Section 01810 “Equipment Testing and Facility Startup.”

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B. Provide qualified personnel and manufacturers’ representatives for the training of OWNER’S personnel and for the demonstration of facility operation in accordance with Section 01820 “Demonstration and Training.”


A. Welding Qualifications: Qualify procedures and personnel according to the applicable code for the materials and work involved: 1. AWS D1.1/D1.1M, "Structural Welding Code – Steel” 2. AWS D1.2/D1.2M, "Structural Welding Code – Aluminum” 3. AWS D1.3, "Structural Welding Code - Sheet Steel” 4. AWS D1.4, "Structural Welding Code - Reinforcing Steel” 5. AWS D1.6, “Structural Welding Code – Stainless steel”

B. Welding Qualifications: Qualify procedures and operators according to ASME Boiler and Pressure Vessel Code.

C. Welding procedures and testing shall comply with ANSI B31.1.0, “Standard Code for Pressure Piping, Power Piping,” and the AWS Welding Handbook.

D. Soldering and Brazing Procedures shall conform to ANSI B9.1, “Standard Safety Code for Mechanical refrigeration.”

E. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.


A. Section 01600 “Product Requirements” provides the administrative and procedural requirements for selection of products for use in Project; product delivery, storage, and handling; manufacturers' standard warranties on products; special warranties; product substitutions; and comparable products. These requirements are in addition to requirements specified in the individual sections.

B. Section 01700 “Execution Requirements” provides the general procedural requirements governing execution of the Work including, but not limited to, the following: 1. Construction layout. 2. Field engineering and surveying. 3. General installation of products. 4. Progress cleaning. 5. Starting and adjusting. 6. Protection of installed construction. 7. Correction of the Work.

1.9 WARRANTY

A. Special Warranty: Special warranties, in addition to the two year general construction warranty, are specified in various Sections. The special warranty time period starts with the date of Substantial Completion, unless specified otherwise.

PART 2 - PRODUCTS

2.1 MATERIALS AND EQUIPMENT

A. Furnish new and unused materials, products, and equipment of domestic manufacturer, unless otherwise specified. Where two or more units of the same type or class of equipment are required, provide units of a single manufacturer.

B. Product selection procedures and substitution procedures are described in Section 01600 “Project Requirements.”

C. Motors

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1. Comply with NEMA designation, temperature rating, service factor, enclosure type, and efficiency requirements for motors specified in applicable motor sections of Division 11. a. Motor Sizes: Minimum size as indicated. If not indicated, large enough so

driven loads will not require motor to operate in service factor range above 1.0. b. Controllers, Electrical Devices, and Wiring: Comply with requirements for

electrical devices and connections specified in Division 16 Sections.

D. Control Panels: Equipment manufacturer furnished control panels shall comply with the requirements of Section 11009 “Common Control Panel Requirements for Equipment.”

2.2 GENERAL FINISH REQUIREMENTS

A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.

B. Protect mechanical finishes on exposed surfaces from damage by applying a strippable, temporary protective covering before shipping.

2.3 NOISE AND VIBRATION

A. Select equipment to operate with minimum noise and vibration. If objectionable noise or vibration is produced, or transmitted to or through the building structure by equipment, piping, ducts, or other parts of Work, rectify such conditions without additional cost to OWNER.

B. If the item of equipment is judged to produce objectionable noise or vibration, demonstrate (without cost to OWNER) that equipment performs within designated limits specific to the equipment as specified in Division 11. Manufacturer must provide Certificate of Compliance with specifications and specified referenced standards.

2.4 CONCRETE

A. Material: Class “B” concrete mixture for equipment and structural support bases.

2.5 STRUCTRUAL MATERIAL

A. Construct floor stands of structural members or steel pipe as designated in Section 05500 “Metal Fabrications.”

B. Work Platforms. Provide as shown on the Drawings and in accordance with section 05512 “Metal Frames and Work Platforms.”

C. Anchor Bolts. Unless otherwise designated provide Type 316 stainless steel in accordance with Section 05501 “Anchor Bolts, Expansion Anchors, and Concrete Inserts.”

PART 3 - EXECUTION

3.1 GENERAL REQUIREMENTS

A. Space Requirements. Consider space limitations imposed by contiguous work, including clearances required for service, in selection and location of equipment, products, and materials. Do not provide equipment, products, or materials which are not suitable in this respect.

B. Obstructions: 1. The Drawings for work associated with existing facilities, indicate certain information

pertaining to surface and subsurface obstructions obtain from available drawings. Such information is not guaranteed, however, as to accuracy of location or complete information.

2. Before any cutting or trenching operations are begun, verify with Resident Project Representative, utility companies, municipalities, and other interested parties that all

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available information has been provided. Verify locations of existing work have been given.

3. Should obstruction be encountered, whether shown or not, after routing of new work, reroute existing lines, remove obstruction where permitted, or otherwise perform whatever work is necessary to satisfy the purpose of the new work and leave existing service, structures, and facilities in a satisfactory and serviceable conditions.

4. Assume responsibility for and repair any damage to existing utilities, structures, or facilities, whether or not such existing facilities are shown on the drawings.

C. Rough In: 1. Verify final locations for rough-ins with field measurements and with the requirements

of the actual equipment to be connected. 2. Refer to equipment specifications in Divisions 5 through 17 for rough-in requirements.

D. Job Conditions: 1. Examine the areas and conditions under which the Work will be performed. 2. Where ducts, pipes, and other mechanical work are shown in conflict with locations of

structural members, electrical, other equipment and related items, include labor and materials required for extensions, offsets, and supports to clear the encroachments.

3. Although such work is not specifically indicated, furnish and install all supplementary or miscellaneous items, appurtenances, and devices incidental to or necessary for a sound, secure, and complete installation.

4. Verify all dimensions and distances. No additional compensation wil be allowed because of differences between work shown on the Drawings and actual dimensions and distances at the jobsite.

E. Preparation and Coordination With Other trades: 1. Perform coordination work associated with Division 15 Mechanical in accordance with

provisions of specifications, shop drawings, and Drawings, as well as the following: a. Coordinate as necessary with other trades to assure proper and adequate

interface with all the Work. b. Coordinate accepted equipment changes from those scheduled or specified

with other trades affected. Additional compensation to other trades for equipment changes are the responsibility of the contractor making the change.

2. The mechanical drawings are diagrammatic, but are required to be followed as closely as actual construction and work of other trades will permit. Duct and piping arrangement have been designed for maximum economy consistent with good practice and other considerations. Install the systems arranged as shown on the Drawings, except as otherwise approved in advance by the Resident Project Representative.

3. Where items such as diffusers, thermostats, switches, control panels, and related work are not specifically located on the Drawings, locate as determined in the field by the Resident Project Representative. When such items are installed without such specific direction, relocate as directed by the Resident Project Representative and at no additional cost to the OWNER.

3.2 MECHANICAL INSTALLATIONS

A. General: Sequence, coordinate, and integrate the various elements of mechanical systems, materials, and equipment. Comply with the following requirements: 1. Coordinate mechanical systems, equipment, and materials installation with other

building components. 2. Verify all dimensions by field measurements. 3. Arrange for chases, slots, and openings in other building components during progress

of construction, to allow for mechanical installations. 4. Coordinate the installation of required supporting devices and sleeves to be set in

poured-in-place concrete and other structural components, as they are constructed.

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5. Sequence, coordinate, and integrate installations of mechanical materials and equipment for efficient flow of the Work. Give particular attention to large equipment requiring positioning prior to closing in the building.

6. Where mounting heights are not detailed or dimensioned, install systems, materials, and equipment to provide the maximum headroom possible.

7. Coordinate connection of mechanical systems with exterior underground and overhead utilities and services. Comply with requirements of governing regulations, franchised service companies, and controlling agencies. Provide required connection for each service.

8. Install systems, materials, and equipment to conform with approved submittal data, including coordination drawings, to greatest extent possible. Conform to arrangements indicated by the Contract Documents, recognizing that portions of the Work are shown only in diagrammatic form. Where coordination requirements conflict with individual system requirements, refer conflict to the ENGINEER.

9. Install systems, materials, and equipment level and plumb, parallel and perpendicular to other building systems and components, where installed exposed in finished spaces.

10. Install mechanical equipment to facilitate servicing, maintenance, and repair or replacement of equipment components. As much as practical, connect equipment for ease of disconnecting, with minimum of interference with other installations. Extend grease fittings to an accessible location.

11. Install systems, materials, and equipment giving right-of-way priority to systems required to be installed at a specified slope.

B. Protection: Adequately protect work, equipment, fixtures, and materials. At completion of Project, all work shall be clean and in good conditions.

C. Air Filters and Pipe Strainers: Immediately prior to Final Acceptance of Project; inspect, clean and service air filters and pipe strainers. Replace disposable type air filters.

D. Lubrication, Refrigerant, and Oil: 1. Provide a complete charge of correct lubricant and oil for each item of equipment. 2. Provide complete and working charge of proper refrigerant for each refrigerant

system. After each system has been in operation long enough to ensure balance operating conditions, check the charge and modify it for proper operation as required.

3.3 EQUIPMENT AND STRUCTURAL FOUNDATIONS AND SUPPORTS

A. Concrete Pads: Unless otherwise shown on the Drawings, pour equipment concrete pads, 4-inch thickness minimum, on roughened floor slabs. Reinforced concrete pad with No. 4 rebar set 12 inches on center, with 2-inch clearance between top of pad and rebar. Extend outer edges of concrete pad a minimum of 2 inches beyond equipment.

B. Structural Supports: Anchor structural supports on 4-inch minimum concrete pads. Adjust height of concrete pads as required to accommodate floor slopes and height of platforms and related work.

C. Ceiling-Mounted Equipment: Hang from suitable brackets, platform framing or similar supports fabricated of structural members. Apply designated protective coating system in accordance with Section 09910 “Painting and Protective Coatings.”

END OF SECTION

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PIPING SYSTEM, BASIC MATERIALS AND METHODS F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15015 PIPING SYSTEM, BASIC MATERIALS AND METHODS.DOC

SECTION 15015 PIPING SYSTEM, BASIC MATERIALS AND METHODS

PART 1 - GENERAL



1.2 SUMMARY

A. Piping materials and installation methods common to the piping system sections of Division 15 and includes joining materials, piping specialties, and basic piping installation instructions. 1. All exposed, submerged, and buried process, plant and station piping including new

piping systems and modifications to existing systems. 2. Raw water, potable water, sanitary sewers, storm drains and culverts serving plant or

station as shown on Drawings.

B. Section Includes: 1. Pipe Joining Materials 2. Transition Fittings 3. Insulating Flanges, Couplings and Unions 4. Connectors and Couplings 5. Pipe Sleeves 6. Expansion Joints

C. Related Sections: 1. Section 02320 "Excavation, Trenching, and Backfilling for Utilities" for the excavation,

trenching, and backfilling for buried piping systems. 2. Division 15 for related piping, valves, and support systems.

1.3 REFERENCES AND DEFINITIONS

A. References: 1. American National Standards Institute (ANSI):

a. B9.1 Standard Safety Code for Mechanical Refrigeration b. B31.3 Power Piping Code c. B31.3 Process Piping Code d. B31.9 Building Service Piping Code

2. ASTM International (ASTM): a. A 53 – Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated,

Welded and Seamless b. B 32 – Specification for Solder Metal c. B 813 – Specification for Liquid and Paste Fluxes for Soldering Copper and

Copper Alloy Tube d. B 828 – Practice for Making Capillary Joints by Soldering of copper and

Copper Alloy Tube and fittings e. C 1173 – Specification for Flexible Transition Couplings for underground Piping

Systems f. D 1785 – Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules

40, 80, and 120 g. D 2564 – Specification for Solvent Cements for Poly(Vinyl Chloride) (PVC)

Plastic Piping systems h. D 2672 – Specification for Joints for IPS PVC Pipe Using Solvent Cement i. D 2846 – Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic

Hot- and Cold-Water distribution Systems

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j. D 2855 – Practice for Making Solvent-Cemented Joints with Poly(Vinyl Chloride) (PVC) Pipe and Fittings

k. D 3139 – Specifications for Joints for Pressure Pipes Using Flexible Elastomeric Seals

l. D 3212 – Specification for Joints for Drain and Sewer Pipes using Flexible Elastomeric Seals

m. E 814 Test Method for Fire Tests of Through-Penetration Fire Stops n. F 402 – Practice for Safe Handling of Solvent Cements, Primers, and Cleaners

Used for Joining thermoplastic Pipe and Fittings o. F 656 – Specifications for Primers for Use in Solvent Cement Joints of Poly

(Vinyl Chloride) (PVC) Plastic Pipe and Fittings p. F 493 – Specification for Solvent Cements for Chlorinated Poly (Vinyl Chloride)

(CPVC) Plastic Pipe and Fittings q. F 593 – Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs r. F 594 – Specification for Stainless Steel Nuts

3. American Society of Mechanical Engineers (ASME): a. A13.1 Scheme for Identification of Piping Systems b. B1.20.1 Pipe Threads, General Propose, Inch c. B16.21 Nonmetallic Flat Gaskets for Pipes Flanges d. B18.2.1 Square and Hex Bolts and Screws, Inch Series

4. American Welding Society (AWS): a. A5.8 Specification for Filler Metals for brazing and Braze Welding b. D1.1 Structural Welding Code Steel c. D10.12 Guide for Welding Mild Steel Pipe

5. American Waterworks Association (AWWA): a. C110 – Standard for Ductile-Iron and Gray-Iron Fittings, 3 In. Through 48 In.

(76 mm Through 1,219 mm) for Water b. C219 – Standard for Bolted, Sleeve-Type Couplings for Plain-End Pipe

6. National Sanitation Foundation (NSF): a. NSF/ANSI 61 – Drinking Water Components – Health Effects

B. Definitions: 1. Piping Systems: Includes all piping, fittings, valves, specials, hangers and supports,

and related items required for a complete piping system. 2. Ferrous Metal: Iron, steel, stainless steel, and alloys with iron as principal component. 3. Nonmetallic: PVC, CPVC, PE, HDPE, and FRP. 4. Nonferrous Metals: Copper 5. Wetted or Submergence:

a. Submerged, or less than one foot above the maximum liquid surface of water holding structures.

b. Below top of channels, under cover of slabs of channels or tanks. c. In other damp or covered locations (e.g., vaults, wetwells, utility corridors, etc.)

6. Exposed or Atmospherically Exposed Piping Systems: All piping systems exposed to the atmosphere (not buried, submerged, wetted or embedded). This designation includes insulated piping inside chases, or piping hidden from view.

7. Texas Administrative Code (TAC): a. Chapter 217 –Design Criteria for Sewerage Systems b. Chapter 290 Subchapter D – Rules and Regulations for Public Water Systems

1.4 SYSTEM DESIGN DESCRIPTION

A. General: 1. The Drawings and Specifications are not all inclusive of explicit piping details; provide

piping in accordance with the laws and regulations and intended use, including: a. Power Piping: ANSI/ASME B31.1 Code. b. Process Piping: ANSI/ASME B31.3 Code. c. Building Service Piping: ANSI/ASME B31.9 Code, as applicable.

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d. Sanitary Building Drainage and Vent Systems: ICBO/APMO Uniform Plumbing Code.

2. Buried Piping: Provide to be suitable for design conditions as follows: a. H20-S16 traffic load (AASHTO Standard Highway Specifications for Bridges)

with 1.5 impact factor. b. Piping both with and without internal pressure.

3. Hangers and Support Systems: Provide an engineered system in accordance with Section 15060 “Hangers and Supports for Piping Systems.”

4. Pressure Testing and Disinfection of Pipelines: Refer to Section 15070 “Field Testing of Piping Systems” for testing of gravity and pressure piping systems; the disinfection of potable water systems; and to the individual piping system Sections for specific requirements.

B. Design Requirements: 1. The configuration and layout of various piping systems are shown in the Drawings.

The types of pipe and joints, and embedment (if buried) to be used for each system are shown on the drawings or included in the appropriate specification Sections.

2. In certain locations, pipe supports, anchors, and expansion joints have been indicated on the drawings, but no attempt has been made to indicate every pipe support, anchor, and expansion joint.

3. It shall be the CONTRACTOR'S responsibility to provide a complete system of pipe supports, to provide expansion joints, and to provide restraints and anchor all piping, in accordance with the requirements set forth herein. Additional pipe supports may be required adjacent to expansion joints, couplings, or valves.

4. Pipe and fittings shown on yard piping drawings are general in nature. CONTRACTOR shall determine exact lengths and fittings required and make field adjustments necessary to complete piping and avoid conflicts.

5. Changes to the plan and profile of piping shall be submitted to ENGINEER for approval.

C. Restrained Pipe and Fitting Joints, Buried Piping: 1. Restrained joints shall be used for a sufficient distance from each bend, tee, elbow,

plug, or other fitting to resist thrust that will develop at the design pressure. 2. CONTRACTOR shall provide restraint length calculations in accordance with AWWA

M41 based on the laying conditions, soil conditions, depth of cover, and pressures to determine the number of restrained joints that will be required.

3. For the purposes of thrust restraint, design pressures shall be the working pressure shown, plus the additional surge allowance for potable water, service water, and pump discharge piping. The design pressure shall be 1.5 times the design test pressure indicated for all other piping.

1.5 SUBMITTALS

A. Comply with Section 01300 “Project Documentation.”

B. Product Data: Submit product data on each product item to be installed.

C. Shop Drawings: Provide shop drawings for piping systems, organized by plant areas or individual piping systems. Prepare drawings to scale (1/4-inch = 1 foot 0 inch minimum), with the following information: 1. Type of piping including materials, fittings, weights, linings, and coatings. A code or

key to product data sheet may be used. 2. Location and type of joints, fittings, taps, supports, restraint systems, kickers, and

blocking (as applicable). Identify by catalog number or shop drawing detail number. 3. Provide information on interior linings and exterior coatings. 4. Identify the exact number of restrained joints, as well as the length of restrained joint

piping for pressure buried piping.

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D. Specials: Provide fabrication drawings for specials including fabricated fittings, wall pipes, and wall sleeves. Show dimensions and materials of construction.

E. Before starting fabrication, CONTRACTOR shall provide ENGINEER with pipe design calculations, the proposed engineered hanger and support systems, and specials, which shall incorporate the following information: 1. Laying plan identifying all restrained joints, details of standard pipe section, special

fittings, pipe supports, and bends. 2. Piping components shall be numbered or otherwise sequence designated. 3. Outlets and bends shall be made up into special lengths so that, when installed, they

will be located as indicated. 4. Each pipe and fitting shall be marked indicating class of pipe and location number in

pipe laying plan. Markings shall be coded to the Shop drawings.

F. Quality Control Submittals: 1. Welding certificates. 2. Field Test Reports: For each pressure testing of piping systems and field-testing

specified in other piping systems sections. 3. Affidavits:

a. Manufacturer’s Certificate of Compliance with reference standards. b. Laboratory Testing Equipment: Certified calibrations, manufacturer’s product

data and test procedures. c. Certified welding inspection and test results.


A. Steel Support Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code."

B. Steel Piping Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel Code: Section IX, "Welding and Brazing Qualifications." 1. Comply with provisions in ASME B31 Series, "Code for Pressure Piping." 2. Certify that each welder has passed AWS qualification tests for welding processes

involved and that certification is current. 3. Welding procedures and testing shall comply with ANSI B31.1.0, “Standard Code for

Pressure Piping, Power Piping,” and the AWS Welding Handbook. 4. Soldering and Brazing Procedures shall conform to ANSI B9.1, “Standard Safety Code

for Mechanical Refrigeration.”

C. Comply with ASME A13.1 for lettering size, length of color field, colors, and viewing angles of identification devices.


A. Comply with the requirements of Section 01600 “Product Requirements” and as described in the following paragraphs.

B. Acceptance at Site: 1. General: Comply with manufacturer's instructions for unloading, storage, and handling

at Project site. 2. Delivery and Handling:

a. Do not deliver piping materials to project site prior to ENGINEER'S review of required submittals.

b. Unload and handle piping materials using proper material handling equipment. Use heavy canvas or nylon slings to lift pipe and fittings to protect coatings.

c. Do not drop, roll, skid piping materials. d. Take such additional precautions as necessary to avoid damaging piping

materials and coatings thereon.

C. Storage and Protection:

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1. Store piping materials in a manner that will reduce risk of damage. 2. Block piping materials to prevent rolling. 3. Protect materials from weather and sun as recommended by the manufacturer. 4. Provide factory-applied plastic end-caps on each length of pipe and tube, except for

concrete, corrugated metal, hub-and-spigot, and clay pipe. Maintain end-caps through shipping, storage and handling to prevent pipe-end damage and prevent entrance of dirt, debris, and moisture.

5. Protect stored pipes and tubes. Elevate above grade and enclose with durable, waterproof wrapping. When stored inside, do not exceed structural capacity of the floor.

6. Protect flanges, fittings, and specialties from moisture and dirt by inside storage and enclosure, or by packaging with durable, waterproof wrapping. Attach protectors over entire gasketed surface of flanges.

7. Flexible piping shall be stored in shaded area 24-hours prior to installation.


A. Field Measurements: Verify actual dimensions of openings, construction contiguous with work, and related items by field measurements before fabrication.

B. Flange Coordination: Coordinate the dimensions, hole drillings and type of flange face (flat or raised) of the flanges furnished with companion flanges of valves, pumps and equipment to be connected to or installed in the piping.

C. NSF Certified: All surfaces and materials in contact with water or in contact with a chemical being added to water that is being treated for potable water use and conveyance, shall comply with the requirements of the Safe Drinking Water Act and shall conform to NSF-61. Product shall bear the mark or seal of an accredited testing laboratory.

1.9 COORDINATION

A. Coordinate installation of required supporting devices and set sleeves in poured-in-place concrete and other structural components as they are constructed.

B. Coordinate installation of identifying devices after completing covering and painting if devices are applied to surfaces.

C. Coordinate size and location of concrete bases. Formwork, reinforcement, and concrete requirements are specified in Division 3.

D. Coordinate installation of piping systems with other trades; such as electrical, instrumentation, fire protection, and HVAC ducts.

PART 2 - PRODUCTS

2.1 PIPING

A. As specified in the various Division 15 Sections, the Piping Schedule, and as shown on the Drawings.

B. Diameters Shown: 1. Standardized Products: Nominal Size. 2. Fabricated Steel Piping (Except Cement-Lined): Outside diameter, ASME B36.10M.

2.2 PIPE JOINING MATERIALS

A. Pipe-Flange Gasket Materials: Suitable for chemical and thermal conditions of piping system contents. 1. ASME B16.21, nonmetallic, flat, asbestos free, 1/8-inch maximum thickness, unless

otherwise indicated.

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a. Full-Face Type: For flat-face, Class 125, cast-iron and cast-bronze flanges. b. Narrow-Face Type: For raised-face, Class 250, cast-iron and steel flanges.

2. AWWA C110, rubber, flat face, 1/8 inch thick, unless otherwise indicated; and full-face or ring type, unless otherwise indicated.

B. Flange Bolts and Nuts: 1. ASME B18.2.1, carbon steel, unless otherwise indicated. 2. Exposed: ASTM A307, Grade B, hex head bolts; ASTM A563, Grade A or B, hex head

nut; and ASTM F436 hardened steel washers. Corten acceptable for mechanical joints.

3. Buried: ASTM A193 or ASTM A320, Type 316 stainless steel bolts; ASTM A194, Type 316, hex head nuts/ and washers of the same material as bolts.

4. Wetted and Submerged: ASTM A193 or ASTM A320, Type 316 stainless steel bolts; ASTM A194, Type 316, hex head nuts/ and washers of the same material as bolts.

C. Segmented Mechanical Couplings: Provide when designated on the Drawings or as an option to flanges for above ground piping, segmented mechanical couplings may be used. 1. Housing: Ductile iron conforming to ASTM A-536, grade 65-45-12, with orange enamel

coating. 2. Coupling Gasket: Grade “E” EDPM. 3. Bolts and Nuts: Heat-treated plated carbon steel, trackhead meeting physical and

chemical requirements of ASTM A-449 and physical requirements of ASTM A-183. 4. Victaulic Style 77 standard flexible couplings or equivalent.

D. Plastic, Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping system manufacturer, unless otherwise indicated.

E. Solder Filler Metals: ASTM B 32, lead-free alloys. Include water-flushable flux according to ASTM B 813.

F. Brazing Filler Metals: AWS A5.8, BCuP Series, copper-phosphorus alloys for general-duty brazing, unless otherwise indicated; and AWS A5.8, BAg1, silver alloy for refrigerant piping, unless otherwise indicated.

G. Welding Filler Metals: Comply with AWS D10.12/D10.12M for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded.

H. Solvent Cements for Joining Plastic Piping: 1. CPVC Piping: ASTM F 493. 2. PVC Piping: ASTM D 2564. Include primer according to ASTM F 656.

I. Fiberglass Pipe Adhesive: As furnished or recommended by pipe manufacturer.

2.3 TRANSITION FITTINGS

A. Transition Fittings, General: Same size as, and with pressure rating at least equal to and with ends compatible with, piping to be joined.

B. Transition Couplings NPS 1-1/2 and Smaller: 1. Underground Piping: Manufactured piping coupling or specified piping system fitting. 2. Aboveground Piping: Specified piping system fitting.

C. AWWA Transition Couplings NPS 2 and Larger: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Cascade Waterworks Mfg. Co. b. Dresser, Inc.; DMD Div. c. Ford Meter Box Company, Inc. (The); Pipe Products Div. d. JCM Industries. e. Smith-Blair, Inc.

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f. Viking Johnson. 2. Description: AWWA C219, metal sleeve-type coupling for underground pressure

piping.

D. Plastic-to-Metal Transition Fittings: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Spears Manufacturing Co.

2. Description: CPVC and PVC one-piece fitting with manufacturer's Schedule 80 equivalent dimensions; one end with threaded brass insert, and one solvent-cement-joint or threaded end.

E. Plastic-to-Metal Transition Unions: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Colonial Engineering, Inc. b. NIBCO INC. c. Spears Manufacturing Co.

2. Description: CPVC and PVC four-part union. Include brass or stainless-steel threaded end, solvent-cement-joint or threaded plastic end, rubber O-ring, and union nut.

F. Flexible Transition Couplings for Underground Nonpressure Drainage Piping: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Cascade Waterworks Mfg. Co. b. Fernco, Inc. c. Mission Rubber Company. d. Plastic Oddities.

2. Description: ASTM C 1173 with elastomeric sleeve ends same size as piping to be joined, and corrosion-resistant metal band on each end.

2.4 INSULATING FLANGES, COUPLINGS AND UNIONS

A. Dielectric Fittings, General: Assembly of copper alloy and ferrous materials or ferrous material body with separating nonconductive insulating material suitable for system fluid, pressure, and temperature.

B. Dielectric Unions: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Capitol Manufacturing Co. b. Central Plastics Company. c. Epco Sales, Inc. d. Hart Industries, International, Inc. e. Watts Water Technologies, Inc. f. Zurn Plumbing Products Group; Wilkins Div.

2. Description: Factory fabricated, union, NPS 2 and smaller. a. Pressure Rating: 150 psig minimum at 180 deg F unless otherwise specified. b. End Connections: Solder-joint copper alloy and threaded ferrous; threaded

ferrous.

C. Dielectric Flanges:

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1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: a. Capitol Manufacturing Co. b. Central Plastics Company. c. Epco Sales, Inc. d. Watts Water Technologies, Inc.

2. Description: Factory-fabricated, bolted, companion-flange assembly, NPS 2-1/2 to NPS 4 and larger. a. Pressure Rating: 150 psig minimum unless otherwise specified. b. End Connections: Solder-joint copper alloy and threaded ferrous; threaded

solder-joint copper alloy and threaded ferrous.

D. Dielectric-Flange Kits: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Advance Products & Systems, Inc. b. Calpico, Inc. c. Central Plastics Company. d. Pipeline Seal and Insulator, Inc.

2. Description: Non-conducting materials for field assembly of companion flanges, NPS 2-1/2 and larger. a. Pressure Rating: 150 psig minimum unless otherwise specified. b. Gasket: Neoprene or phenolic. c. Bolt Sleeves: Phenolic or polyethylene. d. Washers: Phenolic with steel backing washers.

E. Dielectric Couplings: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Calpico, Inc. b. Lochinvar Corporation.

2. Description: Galvanized-steel coupling with inert and noncorrosive, thermoplastic lining, NPS 3 and smaller. a. Pressure Rating: 300 psig at 225 deg F unless otherwise specified. b. End Connections: Threaded.

F. Dielectric Nipples: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers

offering products that may be incorporated into the Work include, but are not limited to, the following: a. Perfection Corporation. b. Precision Plumbing Products, Inc. c. Victaulic Company.

2. Description: Electroplated steel nipple with inert and noncorrosive, thermoplastic lining. a. Pressure Rating: 300 psig at 225 deg F unless otherwise specified. b. End Connections: Threaded or grooved.

2.5 CONNECTORS AND COUPLINGS

A. General: Unless otherwise specified; 1. Type 316 stainless steel bolts, fasteners, tie rods and accessories are required for

connectors intended for buried, wetted, or submerged service.

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2. Carbon steel bolts, fasteners, tie rods and accessories are required in exposed atmospheric service. Coat items in accordance with Section 09910 “Painting and Protective Coatings.”

B. Elastomer Bellows Connector: 1. Type: Fabricated spool, with single filled arch. 2. Materials: Nitrile tube and neoprene cover. 3. End Connections: Flange, 125-lb ANSI B16.1 standard, with elastomeric face and

steel retaining rings. 4. Working Pressure: 190 psig minimum, size 12-inch and smaller. 5. Thrust Restraint: Manufacturer designed control rods, fasteners, and accessories to

limit travel of elongation and compression. 6. Manufacturers and Products:

a. Garlock; Style 204 b. Goodall rubber Co. c. General Rubber Corp.

C. Flexible Type Couplings (Steel and Stainless Steel Pipe): 1. Design: Provide thrust ties across flexible couplings. 2. Body and Middle ring: Carbon or Type 316 stainless steel. 3. Followers: Ductile iron, malleable iron or Type 316 stainless steel. 4. Bolts: Carbon steel or Type 316 stainless steel. 5. Gaskets: EPDM 6. Materials of construction of coupling, closure plates, end rings, and fasteners to match

piping materials on which coupling is employed, as well as whether it is exposed, wetted or submerged service.

7. Manufacturer and Product: a. Dresser; Style 128 b. Smith-Blair; Style 912

D. Split Sleeve Couplings (Steel and Stainless Steel Pipe): 1. Design: Double arch, with built-in thickened shoulders. Full joint restraint achieved for

two times test pressure by weld-on end rings. Closure plates and sealing pad integral with coupling.

2. Gaskets: EDPM O-ring style. 3. Joint Deflection: Up to 2 degree. 4. Carbon steel metal components to have factory-applied fusion bonded epoxy coating

(7 MDFT). 5. Materials of construction of coupling, closure plates, end rings, and fasteners to match


6. Manufacturer and Product: Victaulic, Inc.; Depend-O-Lok Model FxF, Type 2 Coupling, or equal.

E. Flanged Coupling Adapters (FCA) (Ductile Iron and Steel Pipe): 1. Design: Provide thrust across flexible coupling adapters. 2. Body: Carbon steel conforming to AWWA C207. 3. Flange: AWWA C207 or ANSI Standards. 4. Bolts: Carbon steel or 316 stainless steel. 5. Gaskets: EDPM. 6. Carbon steel metal components to have factory-applied fusion bonded epoxy coating

(7 MDFT). 7. Materials of construction of coupling, closure plates, end rings, and fasteners to match


8. Manufacturer and Product: a. Dresser; Style 128 b. Smith-Blair; Style 912

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F. Wedge Action Restraints (Ductile Iron and PVC Pipe): 1. Design: Wedges and wedge actuating components are incorporated into the design of

the follower gland. 2. Material: Ductile iron, ASTM A536, Grade 65-45-12; wedges BHN 370 minimum. 3. Nuts: Designed with torque-limiting twist-off nuts, exposing a bolt head sized to permit

adjustment and removal of joint restraint. 4. Chemical and nodularity test shall be performed as recommended by Ductile Iron

Society on a per ladle basis. 5. Traceability: Provide material traceability records. 6. Coating:

a. Wedge Assembly: Two coats of liquid Xylan fluoropolymer, heat cured. b. Casting Body: Polyester based powder, electrostatically applied and heat

cured, providing corrosion, impact and UV protection. 7. Approvals:

a. Ductile Iron Pipe Restraints: 1) Underwriters Laboratories: Size 3-inch through 24-inch. 2) Factory Mutual: Size 3-inch through 12-inch.

b. PVC Pipe Restraints: 1) Underwriters Laboratories: Size 4-inch through 12-inch. 2) Factory Mutual: Size 4-inch through 12-inch. 3) Size 4-inch through 24-inch comply with ASTM F1674.

8. Manufacturer and Product: a. Ductile Iron Pipe: EBAA Iron Megalug 1100 series. b. PVC Pipe: EBAA Iron Megalug 2000 PVC series.

2.6 PIPE SLEEVES

A. Mechanical sleeve seals for pipe penetrations: 1. Pipe to wall/casing penetration closures shall be modular mechanical type, consisting

of interlocking synthetic rubber links shaped to continuously fill the annular space between pipe or conduit and wall/casing opening. Once expanded, the mechanical seal shall provide a watertight seal.

2. Elastomeric element size and material shall be selected per manufacturer recommendations. Assemble with ASTM A276, Type 316 stainless steel bolts and nuts.

3. Pressure end plates shall be either Type 316 stainless steel or manufactured of glass reinforced plastic, with a minimum tensile strength of 27,000 psi.

4. Sized: According to manufacturer’s recommendations for the size of pipe shown; to provide a watertight seal between pipe and wall sleeve opening.

5. Available Manufacturers: a. Advance Products & systems, Inc. (Innerlynx) b. Pipeline Seal & insulator, Inc. (Link-Seal)

B. Galvanized-Steel Sheet Sleeves: 0.0239-inch minimum thickness; round tube closed with welded longitudinal joint.

C. Steel Pipe Sleeves: ASTM A 53/A 53M, Type E, Grade B, Schedule 40, galvanized, plain ends.

D. Cast-Iron Sleeves: Cast or fabricated "wall pipe" equivalent to ductile-iron pressure pipe, with plain ends and integral waterstop, unless otherwise indicated.

E. Molded PVC Sleeves: Permanent, with nailing flange for attaching to wooden forms.

F. PVC Pipe Sleeves: ASTM D 1785, Schedule 40.

G. Molded PE Sleeves: Reusable, PE, tapered-cup shaped and smooth outer surface with nailing flange for attaching to wooden forms.

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H. Insulated and Encased Pipe Sleeve: Conforming to Pipe Shields, Inc.; Models WFB<WFB-CS and –CW Series, as applicable.

I. Seepage Ring: Provide a seepage ring in middle of wall sleeve as follows: 1. 3/16-inch minimum thickness, centered between sleeve ends for water stoppage on

sleeves located in exterior or water bearing walls. 2. Outside Diameter: 3-inches grater that pipe sleeve outside diameter. 3. Continuously fillet weld on each side all around.

J. Voids between sleeves or core-drilled openings and pipe or conduit passing through fire rated assemblies shall be fire stopped to comply with requirements of ASTM E 814.

2.7 EXPANSION JOINTS

A. Elastomer Bellows: 1. Type: Reinforced, molded wide-arch. 2. End connections: Flanged, 125-lb ANSI B1.1 standard, with Type 316 stainless steel

retaining rings. 3. Washers: Over the retaining rings to provide a leak proof joint under test pressure. 4. Thrust Protection: Manufacturer designed and supplied control rods, fasteners, and

accessories to protect bellows from overextension at test pressures. 5. Tube and Bellows Arch Lining: EDPM. 6. Rated Temperature: 250oF. 7. Rated Deflection and Pressure:

a. Lateral Deflection: 3/4-inch minimum. b. Burst Pressure: four times rated pressure. c. Compression Deflection at Minimum Pressure: 1/2-inch at 250 psig.

8. Manufacturer and Product: a. Holz Rubber Company, Inc. b. Mercer Rubber Co.; Series 500 c. General Rubber Corp. d. Goodall Rubber Co.

2.8 LININGS AND COATINGS

A. Interior Pipe Linings: Prepare, prime, and finish pipe interior in accordance the applicable piping system Division 15 Sections and Section 09910 “Painting and Protective Coatings.”

B. Exterior coatings: Prepare, prime, and finish pipe exterior in accordance the applicable piping system Division 15 Sections and Section 09910 “Painting and Protective Coatings.”

2.9 IDENTIFICATION

A. Provide piping, valve, equipment, and related product identification devices in accordance with Section 10952 “Identification, Stenciling, and Tagging.”

2.10 HANGERS AND SUPPORTS

A. Provide hangers and supports as shown on the drawings and in accordance with Section 15060 “Hangers and Supports for Piping Systems.”

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PART 3 - EXECUTION

3.1 GENERAL INSTALLATION REQUIREMENTS

A. CONTRACTOR shall be responsible for, develop, and comply with the trench safety plan and a confined space entry plan in accordance with Section 02260 “Excavation Support and Protection.”

B. CONTRACTOR shall provide a dewatering system of sufficient scope, size, and capacity to control hydrostatic pressures and to lower, control, remove, and dispose of ground water and permit excavation and construction to proceed on dry, stable subgrades.

C. Excavation, trenching and backfilling of trenches for buried utilities shall comply with the requirements of Section 02320 “Excavation, Trenching, and Backfilling for Utilities.”

D. Install all piping systems in accordance with the Drawings, Specifications, reviewed shop drawings and manufacturer's installation instructions. Pipe and fitting materials shall comply with the individual Division 15 piping system sections.

E. Examine all piping materials prior to installation and replace items that are damaged or otherwise defective.

F. CONTRACTOR shall mark actual flow line or top of pipe elevations and actual coordinates on record drawings when pipelines are being installed.

G. Thoroughly clean inside of all piping, valves, and accessories, and outside of all materials which will be exposed. Clean before installation and maintain in that condition until accepted by OWNER.

H. Provide secure temporary caps or plugs over all pipe openings at the end of each day to prevent foreign material from entering the piping systems. Brace pipe to prevent it from floating.

I. Do not modify structures, equipment, or piping for the purpose of installing piping unless specifically authorized by the ENGINEER.

J. All piping systems shall be cleaned and tested prior to making connections at structures and to existing pipe systems. Small diameter pipes shall be flushed and large diameter pipes shall have mandrels pulled or other acceptable verification furnished that pipes are clean and no construction debris remains. Temporary blocking and forms used to grout inverts and blockouts shall be removed and manholes and pipes shall be tested before payment will be approved for the last 10 percent of the respective pipe pay estimate items.

3.2 PIPING FLEXIBILITY PROVISIONS

A. General: Install flexible couplings to facilitate installation of piping, connections to equipment and pumping units, and to permit disassembly of valve, instrumentation components in accordance with approved Shop Drawings.

B. Flexible Joints at Concrete Backfill or Encasement: Install within 18-inches from the termination of any concrete backfill or encasement.

C. Flexible Joints at Concrete Structures: 1. Install 18-inches or less from the face of structure; joint may be flush with face. 2. Install a second flexible joint, whether shown or not:

a. Pipe Diameter 18-Inches and Smaller: Within 18-inches of the first flexible joint. b. Pipe Diameter Larger Than 18-Inches: Within one pipe diameter of the first

flexible joint.

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3.3 DIELECTRIC FITTING APPLICATIONS

A. Dry Piping Systems: Connect piping of dissimilar metals with the following: 1. NPS 2 and Smaller: Dielectric unions. 2. NPS 2-1/2 to NPS 12: Dielectric flanges or dielectric flange kits.

B. Wet Piping Systems: Connect piping of dissimilar metals with the following: 1. NPS 2 and Smaller: Dielectric couplings. 2. NPS 2-1/2 to NPS 4: Dielectric nipples. 3. NPS 2-1/2 to NPS 8: Dielectric nipples or dielectric flange kits. 4. NPS 10 and NPS 12: Dielectric flange kits.

3.4 PIPING INSTALLATION

A. Install piping according to the following requirements and Division 15 Sections specifying piping systems.

B. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on the Coordination Drawings.

C. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.

D. Install piping to permit valve servicing.

E. Install piping at indicated slopes.

F. Install piping free of sags and bends.

G. Install fittings for changes in direction and branch connections.

H. Select system components with pressure rating equal to or greater than system operating pressure.

I. Sleeves are not required for core-drilled holes.

J. Permanent sleeves are not required for holes formed by removable PE sleeves.

K. Penetrations: Install sleeves for pipes passing through concrete and masonry walls and concrete floor and roof slabs. 1. Cut sleeves to length for mounting flush with both surfaces.

a. Exception: Extend sleeves installed in floors of equipment areas or other wet areas 2-inches above finished floor level.

2. Install sleeves in new walls and slabs as new walls and slabs are constructed. a. Steel Pipe Sleeves: For pipes smaller than NPS 6. b. Steel Sheet Sleeves: For pipes NPS 6 and larger, penetrating gypsum-board

partitions. 3. Watertight Penetrations;

a. Provide wall pipes with thrust collars. Wall rings with tapped flanges are not allowed.

4. Non-Watertight Penetrations: a. Pipe sleeves with seep ring or modular mechanical seal. b. Sleeves are not required for core-drilled openings.

5. Existing Walls: Core-drilled openings and use modular mechanical seal. 6. Caulk all sleeves water and air tight. Seal annular space between pipe and sleeve with

fire stopping compound.

L. Verify final equipment locations for roughing-in.

M. Refer to equipment specifications in other Sections for roughing-in requirements.

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N. Isolation Valves: Provide piping systems with line size shutoff valves located at risers, at main branch connections to mains for all equipment, and at other locations as indicated and required.

O. Vent and Drain Valves: 1. Pipe 2-1/2 Inch Diameter and Larger: 3/4-inch vent, 1-inch drain, unless otherwise

shown. 2. Pipe 2-inch and Smaller: 1/2-inch vent. 3/4-inch drain, unless otherwise shown. 3. Install vent and drain valves at low points (drains) and high point (vents) of piping

systems so that these systems can be entirely drained and vented. Provide line size ball valves for all vents and drains.

P. Gravity drain systems beneath slabs shall be ductile iron, except for chemical drains, unless shown specifically on Plans. Encase all piping beneath slabs.

Q. Install cleanouts on sludge piping so that all runs between bends may be accessed and at intervals not exceeding 250 feet on straight runs.

R. All bolts and fasteners on buried or submerged fittings and valves shall be Type 316 stainless steel.

S. Provide taps and connections for flushing, testing, and disinfecting pipeline systems.

T. Provide taps or weld-u-lets with stainless steel ball valves and piping at all high points in the piping systems for addition of air valves.

3.5 PIPING JOINT CONSTRUCTION

A. General: 1. Join pipe and fittings according to the following requirements and Division 2 Sections

specifying piping systems. 2. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe. 3. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before

assembly.

B. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows: 1. Apply appropriate tape or thread compound to external pipe threads unless dry seal

threading is specified. 2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or

damaged. Do not use pipe sections that have cracked or open welds.

C. Welded Joints: Construct joints according to AWS D10.12, using qualified processes and welding operators according to Part 1 "Quality Assurance" Article.

D. Push-on Joints: 1. Comply with the recommendations of the pipe manufacturer relative to gasket

installation and other jointing operations. 2. Prepare pipe ends by removing from bell and spigot ends all lumps, blisters, excess

coal-tar coatings, oil and grease, then wire brush and wipe clean and dry before laying pipe.

3. Install ring gasket and, when seated, apply thin film of lubricant to inside surface of gasket.

4. Set spigot, applying lubricant as necessary, aligning with bell and contacting gasket. 5. Pipe 6-inches and smaller may be driven with a bar lever on end of pipe. 6. For larger pipe, use only approved ratchet-type jacking tool to pull pipe "home."

E. Flanged Joints: 1. Prior to installation of bolts, accurately center and align flanged joints to prevent

mechanical prestressing of flanges, pipe and equipment. Align bolt holes to straddle

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the vertical, horizontal or north-south center line. Do not exceed 3/64-inch per foot of inclination of the flange face from true alignment.

2. Select appropriate gasket material, size, type, and thickness for service application. Install gasket concentrically positioned.

3. Use bolts, nuts, and washers of the designated material for service conditions. Tighten bots progressively to prevent unbalance stress. Draw bolts tight to ensure proper seating of gaskets. Use suitable lubricants on bolt threads.

F. Mechanical Joints: 1. Assemble in accordance with manufacturer’s instructions. Remove all foreign matter

from pipe ends, gaskets, and fittings before installation. 2. Wash ends of pipe, gaskets, and fittings with soapy water before assembly. 3. If effective sealing is not obtained, disassemble joint and clean and reassemble. Over

tightening bolts to compensate for poor installation practice will not be permitted. 4. Mechanical joints shall be suitably restrained to prevent movement.

G. Mechanical Couplings, Rigid: 1. Install per manufacturer’s instructions. Pipe ends shall be clean and smooth. 2. Space between pipe ends shall be at least 1/4-inch, but not more than one inch.

H. Flexible Couplings and Flanged Coupling Adapters: 1. Install per Drawings and in accordance with manufacturer’s instructions at locations to

facilitate removal of equipment, valves, and other elements. 2. All flexible couplings and flanged couplings shall be restrained.

I. Grooved Joints: Assemble joints with grooved-end pipe coupling with coupling housing, gasket, lubricant, and bolts according to coupling and fitting manufacturer's written instructions.

J. Soldered Joints: Apply ASTM B 813 water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook," using lead-free solder alloy (0.20 percent maximum lead content) complying with ASTM B 32.

K. Brazed Joints: Construct joints according to AWS's "Brazing Handbook," "Pipe and Tube" Chapter, using copper-phosphorus brazing filler metal complying with AWS A5.8.

L. Pressure-Sealed Joints: Assemble joints for plain-end copper tube and mechanical pressure seal fitting with proprietary crimping tool to according to fitting manufacturer's written instructions.

M. Plastic Piping Solvent-Cemented Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following: 1. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent

cements. 2. CPVC Piping: Join according to ASTM D 2846. 3. PVC Pressure Piping: Join schedule number ASTM D 1785, PVC pipe and PVC

socket fittings according to ASTM D 2672. Join other-than-schedule-number PVC pipe and socket fittings according to ASTM D 2855.

4. PVC Nonpressure Piping: Join according to ASTM D 2855.

N. Plastic Pressure Piping Gasketed Joints: Join according to ASTM D 3139.

O. Plastic Nonpressure Piping Gasketed Joints: Join according to ASTM D 3212.

P. Plastic Piping Heat-Fusion Joints: Clean and dry joining surfaces by wiping with clean cloth or paper towels. Join according to ASTM D 2657. 1. Plain-End PE Pipe and Fittings: Use butt fusion. 2. Plain-End PE Pipe and Socket Fittings: Use socket fusion.

Q. Bonded Joints: Prepare pipe ends and fittings, apply adhesive, and join according to pipe manufacturer's written instructions.

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3.6 VALVES AND VALVE BOXES

A. Prior to installing valves, remove foreign matter from within the valve. Inspect valves in the open and closed position to verify that all parts are in satisfactorily working condition.

B. Install valves, setting valves plumb, with operators aligned as shown on the Drawings. For buried valves, center valve boxes on valves. Carefully tamp earth around each valve box for a minimum of four feet or to the trench face if less than four feet.

3.7 SECURING AND SUPPORTING

A. Exposed Piping Systems: 1. Engineered Hanger and Support System: The CONTRACTOR provide an engineered

hanger and support system for the various piping systems in accordance with Section 15060 “Hangers and Supports for Piping Systems”; as shown on the Drawings; and as specified herein to maintain the line and grade and prevent the transfer of stress to pumps, equipment and other related work. a. This includes the design of multiple piping supports and trapeze hangers and

the selection of appropriate hangers and anchors to the structures, buildings, and facilities. This design shall be accomplished by a professional engineer license in the state where the Project is to be constructed.

2. Reaction Anchorage and Blocking: Install suitable reaction blocking, struts, anchors, clamps, joint harness, or other adequate means for preventing movement of pipe caused by unbalanced internal liquid pressure. Pressure can be expected at tees, elbows, Y-branches, and other bends, which are installed in piping subjected to internal hydrostatic heads in excess of 15-feet in exposed piping.

B. Buried Piping Systems: 1. Reaction Anchorage and Blocking: Install suitable reaction blocking, struts, anchors,

clamps, joint harness, or other adequate means for preventing movement of pipe caused by unbalanced internal liquid pressure. Pressure can be expected at unlugged tees, Y-branches and bends deflecting 11-1/4 degrees or more, which are installed in piping subjected to internal hydrostatic heads in excess of 30-feet in buried piping.

2. Restrained Joints: a. Unless otherwise indicated on the Drawings, the CONTRACTOR shall

provided restrained pipe joints and fittings in accordance with Part 1 Project Requirements.

b. All fittings shall be restrained using restrained joint pipe and fittings for a sufficient length to resist the internal hydrostatic pressures.

c. Restrained push-on pipe and fittings shall be capable of being deflected after assembly.

d. The design for restrained joints, including the length necessary to resist the design thrust and the approval of the fill material and compaction method, shall be performed and sealed by a professional engineer license in the state where the Project is to be constructed.

e. The above applies to unsaturated soil conditions. In locations where ground water is encountered, the soil density shall be reduced to its buoyant weight for all backfill below the water table and the coefficient of friction shall be reduced to 0.25.

f. Bends and Appurtenances: 1) Provide restrained at all bends. 2) Horizontal changes in pipe direction may be accomplished without the

use of direction-changing fittings. Controlled horizontal longitudinal bending using deflected joints may be used and shall not exceed 50 percent of the manufacturer’s written recommendations.

3) Vertical changes in pipe direction may be accomplished without the use of directional-changing fittings which require vertical thrust blocking and/or joint restraint. Controlled vertical longitudinal bending shall be

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accomplished using deflected joints, resulting in a circular pipe arc where joints do not require restraint. Joint deflections shall not exceed 50 percent of the manufacturer’s written recommendations.

4) Valves, hydrants, and fittings shall be supported by a concrete block or concrete cradle. The weight of these items shall not be supported by the pipe.Concrete

3. Thrust Blocking: When specified on the Drawings or with written approval from the ENGINEER, provide concrete thrust blocking between the fitting and solid, undisturbed ground.

4. In the event that adequate support against undisturbed ground cannot be obtained, install metal harness anchorages consisting of steel rods or bolts across the joint and securely anchored to the pipe and fittings, or other adequate anchorage facilities.

3.8 CORROSION PROTECTION

A. Provide corrosion protection for all steel clamps, rods, bolts, and other metal accessories used in reaction anchorages or joint harness where subject to submergence or contact with earth or other fill material and not encased in concrete. Apply not less than two coats of coal-tar mastic coating material to clean, dry metal surfaces. Allow first to dry prior to application of second coat.

3.9 PIPING CONNECTIONS

A. Make connections according to the following, unless otherwise indicated: 1. Install unions, in piping NPS 2 and smaller, adjacent to each valve and at final

connection to each piece of equipment. 2. Install flanges, in piping NPS 2-1/2 and larger, adjacent to flanged valves and at final

connection to each piece of equipment. 3. Install dielectric fittings at connections of dissimilar metal pipes.

B. Connections with Existing Piping: 1. Field verify all dimensions, sizes, configuration and related items on all existing piping

to which connections are to be made. 2. Connections between new work and existing piping shall utilized suitable fittings for

the conditions encountered. 3. Each connection with an existing pipe shall be made at a time under conditions which

will least interfere with service to the OWNER or to customers, and as authorized by the OWNER. Provide notification 48 hours in advance prior to making connections.

C. Pipe Connections: 1. Piping connections shall be of the type indicated on the Drawings or in the Piping

Schedule provided in the Drawings. 2. Field-welded joints will be permitted only when indicated on the Drawings and will

require approval of the ENGINEER. 3. Field-welded joints will only be permitted at locations where the interior coatings can

be repaired and inspected. 4. Additional flanged, compression sleeve or grooved end couplings may be added by

the CONTRACTOR to facilitate fabrication, handling, transportation and field assembly at no additional cost.

3.10 EQUIPMENT INSTALLATION

A. Install equipment level and plumb, unless otherwise indicated.

B. Install equipment to facilitate service, maintenance, and repair or replacement of components. Connect equipment for ease of disconnecting, with minimum interference with other installations. Extend grease fittings to an accessible location.

C. Install equipment to allow right of way to piping systems installed at required slope.

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3.11 PAINTING

A. Painting of piped systems, valves, specials, hangers and supports, equipment, and components shall be as specified in the various sections and Section 09910 “Painting and Protective Coatings.”

B. Damage and Touchup: Repair marred and damaged factory-painted finishes with materials and procedures to match original factory finish.

3.12 IDENTIFICATION

A. Piping Systems: Install pipe and valve markers, including arrows showing normal direction of flow in Accordance with Section 10952 “Identification, Stenciling, and Tagging.” 1. Plastic markers, with application systems. Install on insulation segment if required for

hot non-insulated piping. 2. Locate pipe markers on exposed piping according to the following:

a. Near each valve and control device. b. Near each branch, excluding short takeoffs for equipment and terminal units.

Mark each pipe at branch if flow pattern is not obvious. c. Near locations where pipes pass through walls or floors or enter inaccessible

enclosures. d. At manholes and similar access points that permit view of concealed piping. e. Near major equipment items and other points of origination and termination.

B. Buried Piping System Identification: 1. Buried water piping systems shall have marking tape installed approximately 12-

inches above the pipe in accordance with Section 02320 “Excavation, Trenching, and Backfilling for Utilities.”

2. Install detectable warning tape above non-metallic pipelines.

C. Equipment: Install engraved plastic-laminate sign or equipment marker on or near each major item of equipment in accordance with Section 10952 “Identification, Stenciling, and Tagging” and the following: 1. Lettering Size: Minimum 1/4 inch high for name of unit if viewing distance is less than

24 inches, 1/2 inch high for distances up to 72 inches, and proportionately larger lettering for greater distances. Provide secondary lettering two-thirds to three-fourths of size of principal lettering.

2. Text of Signs: Provide name of identified unit. Include text to distinguish among multiple units, inform user of operational requirements, indicate safety and emergency precautions, and warn of hazards and improper operations.

D. Adjusting: Relocate identifying devices that become visually blocked by work of this or other Divisions.

E. Wiring: Identify system components, wiring, cabling, and terminals. Comply with requirements for identification specified in Section 10952 “Identification, Stenciling, and Tagging”.

3.13 CONCRETE BASES

A. Concrete Bases: Anchor equipment to concrete base according to equipment manufacturer's written instructions and according to seismic codes at Project. 1. Construct concrete bases of dimensions indicated, but not less than 4 inches larger in

both directions than supported unit. 2. Install dowel rods to connect concrete base to concrete floor. Unless otherwise

indicated, install dowel rods on 18-inch centers around the full perimeter of base. 3. Install epoxy-coated anchor bolts for supported equipment that extend through

concrete base, and anchor into structural concrete floor.

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4. Place and secure anchorage devices. Use supported equipment manufacturer's setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

5. Install anchor bolts to elevations required for proper attachment to supported equipment.

6. Install anchor bolts according to anchor-bolt manufacturer's written instructions. 7. Use 3000-psi, 28-day compressive-strength concrete and reinforcement as specified

in Section "03300 Cast-in-Place Concrete."

3.14 ERECTION OF METAL SUPPORTS AND ANCHORAGES

A. Refer to Section 15060 “Hangers and Supports for Piping Systems” for information on the installation of the engineered hangers and supports for piping systems.

3.15 CONNECTIONS TO EQUIPMENT FURNISHED BY OTHERS

A. Provide service connections to equipment furnished by others, utilizing equipment shop drawings furnished for indicating type, number and location of connecting points. As part of the work, field adjustments as to the type, number, and location may be required. This is considered part of the Work. 1. Roughing-In: Extend service connections to various items of equipment. Temporarily

terminate at proper points as indicated on the shop drawings furnished or as directed. 2. Final Connections: Provide items, such as pipe, fittings, adapters, valves, insulation,

and other materials, required to connect equipment from the rough-in locations. 3. Valves: Provide cut-off valve for each service at rough-in locations, except drains.

3.16 CLEANING OF PIPING SYSTEMS

A. Clean piping systems thoroughly. Purge pipe of construction debris and contamination before placing the system in service. Provide temporarily connections required for cleaning, purging and circulation.

B. Install temporary strainers in front of pumps, tanks, solenoid valves, control valves, and other equipment where permanent strainers are not indicated. Keep these strainers in service until the equipment has been tested, then remove either entire strainer or straining element only. Fit strainers with line size blow off valve.

C. Circulate a chemical cleaner in chilled, heating and condensing water systems; and steam and condensing piping systems to remove mill scale, grease, oil, and silt. Circulate for 48-hours, flush system and replace with clean water. Dispose of chemical solution in accordance with local ordinances. The type and quantity of cleaning chemicals shall be as recommended by the supplier for the service.


A. Testing Agency: Engage a qualified testing agency to perform tests and inspections.

B. Tests and Inspections: 1. Lined carbon steel pipe and fittings shall be inspected by the CONTRACTOR after

installation to ensure linings are intact in accordance with the piping system section and shall certify to that effect. a. Pipe 24-Inches and Smaller: Engage an inspection organization to video

inspect pipe and report findings. 2. Pressure test piping systems in accordance with Section 15070 “Field Testing of

Piping Systems.” 3. Potable water piping systems shall be cleaned, purged, and disinfected in accordance

with Section 02675 “Disinfection of Potable Water Piping and Tanks.” 4. Additional field-testing shall be as described in the individual piping systems sections

of Division 15.

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C. The piping system component(s) will be considered defective if it does not pass tests and inspections.

D. Prepare test and inspection reports.

3.18 SUPPLEMENTS

A. Piping Schedule is provided in the Drawings.

END OF SECTION

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PIPING SYSTEM, DUCTILE IRON PIPE F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15020 PIPING SYSTEM, DUCTILE IRON PIPE.DOC

SECTION 15020 PIPING SYSTEM, DUCTILE IRON PIPE

PART 1 - GENERAL



1.2 SUMMARY

A. Section provides requirements for ductile iron piping system for exposed and buried applications and includes: 1. Mechanical joint, push-on and flanged ductile iron pipe, sizes 4-inch through 24-inch. 2. Mechanical joint and flanged ductile iron and cast iron fittings, sizes 4-inch through

24-inch. 3. Gaskets and fasteners. 4. Protective coatings, linings and encasements.

B. Related Sections: 1. Section 01300 “Project Documentation” 2. Section 15015 “Piping System, Basic Materials and Methods”

1.3 REFERENCES

A. American Water Works Association (AWWA): 1. C104/A21.4 - Cement-Motor Lining for Ductile-Iron Pipe and Fittings for Water. 2. C105/21.5 - Polyethylene Encasement for Gray and Ductile Cast-Iron Piping for Water

and Other Liquids. 3. C110-C21.10 - American National Standard for Gray-Iron and Ductile-Iron Fittings, 3-

inch through 48-inch for Water and Other Liquids. 4. C111/A21.11 - American National Standard for Rubber Gasket Joints for Ductile-Iron

and Gray-Iron Pressure Pipe and Fittings. 5. C115/A21.15 - American National Standard for Flanged Cast-Iron and Ductile-Iron

Pipe with Threaded Flanges. 6. C150/A21.50 - American National Standard for the Thickness Design of Ductile Iron

Pipe. 7. C151/A21.51 - American National Standard for Ductile-Iron Pipe, Centrifugally Cast in

Metal Molds or Sand-Lined Molds, for Water and Other Liquids. 8. C153/A21.10 - Ductile-Iron Compact Fittings for Water Service. 9. C600 - Installation of Ductile Iron Water Mains and Their Appurtenances. 10. C606 - Grooved and Shouldered Joints. 11. M41 - Manual Ductile Iron Pipe and Fittings.

B. ASTM International, Inc. (ASTM): 1. A48 - Specification for Gray Iron Castings. 2. A193 - Specification for Alloy-Steel and Stainless Steel bolting Materials for High

Temperature or High Pressure Service and Other Special Purpose Applications. 3. A194 - Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or

High-Temperature Service, of Both. 4. A307 - Specification for Carbon Steel Bolts and Studs, 60000 PSI Tensile Strength. 5. A320 - Specification for Alloy-Steel and Stainless Steel Bolting Materials for Low

Temperature Service. 6. A536 - Specification for Ductile Iron Castings. 7. A563 - Specification for Carbon and Alloy Steel Nuts. 8. A674 - Standard Practice for Polyethylene Encasement for Ductile Iron Pipe for Water

or other Liquids.

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9. D1330 - Specification for Rubber Sheet Gaskets.

C. National Science Foundation (NSF): 1. NSF/ANSI 61 - Drinking Water Components – Health Effects.

1.4 SUBMITTALS

A. Comply with Section 01330 “Submittal Procedures.”

B. Product Data: For each type of product indicated.

C. Shop Drawings: 1. Pipe layout drawings shall include plan, elevations, sections, details, and attachments

to other work. 2. Pipe layout schedule/drawings including pipeline stationing, elevation, and restrained

joint locations. 3. Schedule of materials furnished. 4. Pipe layout drawings and data shall clearly indicate where pipe requiring special

provisions are to be located, connections to equipment, valves, and related items.

D. Material Certificates: 1. Certificate of Compliance with all applicable and appropriate reference standards

certifying that all pipe, fittings, and specials, and other products and materials furnished, comply with the applicable provision of the Specification.

2. Certification of Adequacy of Design: The Certificate of Adequacy of Design shall show the necessary provisions required in the design of the pipe to comply with applicable sections of this Specification. A Professional Engineer registered in the state where the Project is located shall seal the Certificate of Adequacy of Design.

E. Field quality-control test reports.

1.5 PROJECT REQUIREMENTS

A. Restrained Pipe and Fitting Joints, Buried Piping: 1. Restrained joints shall be used for a sufficient distance from each bend, tee, elbow,

plug, or other fitting to resist thrust that will develop at the design pressure. 2. CONTRACTOR shall provide restraint length calculations in accordance with AWWA

M41 based on the laying conditions, soil conditions, depth of cover, and pressures to determine the number of restrained joints that will be required.

3. For the purposes of thrust restraint, design pressures shall be the working pressure shown, plus the additional surge allowance for potable water, service water, and pump discharge piping. The design pressure shall be 1.5 times the design test pressure indicated for all other piping.

B. Hangers and Supports, Exposed Piping: Refer to Section 15060 “Hangers and Supports for Piping Systems” for requirements for engineered hangers and supports for piping systems to be provided by CONTRACTOR.

PART 2 - PRODUCTS

2.1 PIPE AND FITTINGS

A. General: Ductile iron with a thickness design for the pressures and laying conditions complying with the requirements of AWWA C150 and the manufactured in accordance with AWWA C151. 1. Comply with the following minimum thickness class, unless otherwise indicated in the

Pipe Schedule. a. Class 51, pipe 6-inch and smaller. b. Class 50, pipe 8-inch and larger.

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c. Class 53 for threaded flanged joints. d. Class 53 for grooved end pipe, grooved in accordance with AWWA C606.

B. Mechanical-Joint, Ductile-Iron Pipe: AWWA C151, with mechanical-joint bell and plain spigot end unless grooved or flanged ends are indicated. 1. Mechanical-Joint, Ductile-Iron Fittings: AWWA C110, ductile- or gray-iron standard

pattern or AWWA C153, ductile-iron compact pattern. 2. Glands, Gaskets, and Bolts: AWWA C111, ductile- or gray-iron glands, rubber

gaskets, and steel bolts.

C. Push-on-Joint, Ductile-Iron Pipe: AWWA C151, with push-on-joint bell and plain spigot end unless grooved or flanged ends are indicated. 1. Push-on-Joint, Ductile-Iron Fittings: AWWA C110, ductile or cast iron standard

pattern or AWWA C153, ductile-iron compact pattern. 2. Gaskets: AWWA C111, rubber. 3. Contractor is not required to restrain ductile-iron pipe that is concrete encased under

structures. 4. Contractor is not required to poly-wrap ductile iron pipe that is concrete encased under

structures.

D. Flanged-Joint, Ductile-Iron Pipe: AWWA C151, flanged ends. 1. Flange Joints: Comply with the requirements of AWWA C115.

a. Class 150 or Class 250 as designated on Drawings or Pipe Schedule. 2. Bolting:

a. Exposed: ASTM A307, carbon steel, Grade A hex head bolts; ASTM A563, Grade A hex head nuts; and ASTM F436 hardened steel washers.

b. Submerged or Buried: ASTM A193 or ASTM A320, Type 316 stainless steel bolts; ASTM A194, Type 316, nuts; and washers of the same material as the bolts.

c. Gaskets: 1) Flange, Flat Face: Full-faced, AWWA C111, 1/8-inch thick rubber, factory

cut. 2) Flange, Raised Face: Use flat ring gasket.

2.2 SPECIAL PIPE FITTINGS

A. Ductile-Iron, Flexible Expansion Joints: Compound fitting with combination of flanged and mechanical-joint ends complying with AWWA C110 or AWWA C153. Include 2 gasketed ball-joint sections and 1 or more gasketed sleeve sections, rated for system pressures and for offset and expansion indicated. 1. Available Manufacturers:

a. EBAA Iron Sales, Inc. b. Romac Industries, Inc. c. Star Pipe Products.

B. Ductile-Iron Deflection Fittings: Compound coupling fitting with ball joint, flexing section, gaskets, and restrained-joint ends complying with AWWA C110 or AWWA C153. Include rating for 250-psig minimum working pressure and for up to 15 degrees of deflection. 1. Available Manufacturers:

a. EBAA Iron Sales, Inc.

C. Ductile-Iron Expansion Joints: Three-piece assembly of telescoping sleeve with gaskets and restrained-type, ductile-iron bell-and-spigot end sections complying with AWWA C110 or AWWA C153. Include rating for 250-psig minimum working pressures and for expansion indicated. 1. Available Manufacturers:

a. Dresser, Inc.; DMD Div. b. EBAA Iron Sales, Inc. c. JCM Industries.

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D. Flange adapter: For joining steel pipe to cast iron, provide Dresser Style 127 or equal. Gasket to be BUNA-S, Grade 27.

E. Dismantling Joint: Double-ended flange adapter, allowing longitudinal adjustment in piping system, similar to Dresser Style 131 or equal.

F. Reducing and Transition Coupling: Required for making reduction is sizes of piping; changing classes of piping; or joining steel and cast iron pipe, provide Dresser Style 62 or equal.

2.3 PROTECTIVE COATINGS, LININGS, AND ENCASEMENT

A. Pipe and Fittings Interior: 1. Mortar: Unless otherwise specified in the Piping Schedule, all ductile iron pipe and

fittings shall be provided with a cement-mortar lining in accordance with AWWA C104. A bituminous seal coat shall be applied over the cement-mortar lining in accordance with AWWA C104.

2. Epoxy: When specified in the Piping Schedule, apply a high build, fusion bonded epoxy lining per AWWA C116, minimum 16 mils dry film thickness, per AWWA C116. Epoxy lining shall be suitable for potable water service per NSF 61.

3. Glass Lining: a. Consist of glass completely fused above 1,450 degrees F, with a thickness of 6

to 10 mils and defects, which exposed base metal not greater than 0.1 percent of total lined surface.

b. Hardness shall be greater than 5 on the Mohs scale and lining bonded sufficiently to withstand a metal strain of 0.001-inch/inch without damage to the glass lining.

c. Finished lined pipe shall not deviate more than 0.0125-inch per foot of length from a centerline perpendicular to the flange face or square end of the pipe.

d. Available Manufacturers: Water Works Supply Co., Ferrock MEH-32; Ceramic Coating Co., SL-31; or Ervite Corp., SG-14.

4. Amine-Cured Epoxy: When specified in the Piping Schedule, the inside of pipe, bells, and fittings shall be coated with an amine-cured Novalac epoxy with at least 20 percent by volume of ceramic quartz pigment, 40 mils nominal DFT after the pipe has been solvent cleaned and abrasive blasted. Use Protecto 401 or approved equal.

B. Pipe and Fittings Exterior: 1. Exposed Piping: Provide shop coat primer required for the coating system specified in

Section 09910 “Painting and Protective Systems.” 2. Buried Piping: Provide shop applied 1-mil bituminous coating system per AWWA C151

for pipe and AWWA C110 for fittings.

C. Encasement for Underground Metal Piping: ASTM A 674 or AWWA C105. 1. Form: Sheet or tube. 2. Material: LLDPE film of 0.008-inch minimum thickness or high-density, cross-

laminated PE film of 0.004-inch minimum thickness. 3. Color: Black.

2.4 VENT AND DRAIN VALVES

A. Pipelines 2-1/2-Inch Diameter and Larger: 3/4-inch vent, 1-inch drain, unless indicated otherwise on the Drawings.

B. Pipelines 2-Inch Diameter and Smaller: 1/2-inch vent, 1-inch drain, unless indicated otherwise on the Drawings.

C. Install vents and drains at piping system high points (vents) and low points (drains) as required by final installation configuration. Provide line size ball valves for all vents and drains.

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2.5 INSULATED CONNECTIONS

A. Provide dielectric insulation kits, including gaskets, insulating sleeves and washers for each bolt and nuts, where flanges are to be cathodically insulated. Metal hardware such as backup washers shall be Type 316 stainless steel. Refer to Section 15015 “Piping System, Basic Materials and Methods” for description and additional information.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Comply with the requirements of Section 15015 “Piping System, Basic Materials and Methods.” Drawings indicate general arrangement of piping, fittings, and specialties.

B. Laying Buried Pipe: 1. Install pipe to the lines, grades and elevations shown on the Drawings, complying with

the requirements of AWWA C600. 2. Unless otherwise shown on the Drawings, within the plant site, bury piping with a

minimum cover of 3-feet. Off-site, bury lines 12-inches and smaller with a minimum cover of 4-feet and lines 14-inches and larger with a minimum cover of 5-feet.

3. Do not lay pipe in water, or when the trench or weather is unsuitable for work. Keep water out of trench until jointing is complete. When work is not in progress, close ends of pipe and fittings securely so no trench water, earth or other substances will enter pipes or fittings.

4. Keep the inside of the pipe free from foreign matter during operations by plugging or other approved method.

5. Provide pipe bedding in accordance with the Drawings and Section 02320 “Excavation, Trenching, and Backfilling for Utilities.” Place pipe so that the full length of each section rests solidly upon the pipe bed, with rece3sses excavated to accommodate bells and joints. Take up and relay pipe when the grade or joint is disturbed after laying.

6. Lay pipe with bells facing the direction of the laying except when making enclosures. 7. Buried pipe and fittings shall be polyethylene wrapped in accordance with

AWWA C105. 8. Provide a restrained push-on joint or mechanical joint ten feet from outside face of

structures.

C. Restrained Joints: Unless otherwise indicated on the drawings, the CONTRACTOR shall use mechanical restrained pipe joints and fittings (no thrust blocks). The length of pipe requiring thrust restraint shall be calculated as described in Chapter 13 of AWWA M-11. 1. All joints requiring thrust restraint shall be welded (buried) in accordance with

AWWA C-206 or restrained with mechanical systems (exposed). 2. CONTRACTOR shall design restrained joints based on the specified pressures as

shown in the Piping Schedule or Drawings and in accordance with AWWA M-11. 3. The design for restrained joints, including the length necessary to resist the design

thrust, for the embedded conditions, shall be performed and sealed by a Professional Engineer in the state where the Project is being constructed.

4. CONTRACTOR shall bear all costs for the design and will not receive reimbursement from the OWNER.

3.2 CLEANING

A. All piping systems shall be thoroughly cleaned and flushed and all construction debris or foreign material removed. The CONTRACTOR shall provide all temporary connections, equipment and the like for cleaning.

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A. Sterilization: Clean and sterilized potable water lines in accordance with Section 15070 “Field Testing of Piping Systems.”

B. Piping Tests: Conduct piping tests before joints are covered and after concrete thrust blocks have hardened sufficiently.

C. Hydrostatic Tests: Conduct testing in accordance with Section 15070 “Field Testing of Piping Systems.”

D. Prepare reports of testing activities.

3.4 PIPING SCHEDULE

A. Piping Schedule is provided in the Drawings.

END OF SECTION

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PIPING SYSTEM, POLYVINYL CHLORIDE (PVC) AND CHLORINATED POLYVINYL CHLORIDE (CPVC) F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15030 PIPING SYSTEMS, PVC AND CPVC.DOCX

SECTION 15030 PIPING SYSTEM, POLYVINYL CHLORIDE (PVC) AND

CHLORINATED POLYVINYL CHLORIDE (CPVC)

PART 1 - GENERAL



1.2 SUMMARY

A. Section provides requirements for PVC and CPVC piping systems for exposed and buried applications, pressure and gravity applications and includes: 1. Polyvinyl chloride (PVC) and chlorinated polyvinyl chloride (CPVC) pressure

pipe and fittings in sizes 1/2-inch through 48-inch. 2. Polyvinyl chloride (PVC), Schedule 40 and 80, pressure pipe and fittings. 3. PVC pipe and fittings, gravity sewer and drain

B. Related Sections: 1. Section 01810 “Equipment Testing and Facility Startup” 2. Section 15010 “Basic Mechanical Requirements” 3. Section 15015 “Piping Systems-Basic Materials and Methods” 4. Section 15060“Hangers and Supports for Piping Systems”

C. Related Work: 1. This Section contains material requirements for pipe, fittings, specials, and

appurtenances for PVC and CPVC piping systems, as well as Part 1-General and Part 3-Execution additional requirements not specified in the above referenced Section.

1.3 REFERENCES

A. References: 1. American Waterworks Association (AWWA):

a. C110 – Standard for Ductile-Iron and Gray-Iron Fittings, 3- to 48-in. (80 mm through 1,200 mm) for Water

b. C111 – Standard for Rubber Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings

c. C153 – Standard for Ductile-Iron Compact Fittings for Water Service d. C219 – Standard for Bolted, Sleeve-Type Couplings for Plain-End Pipe e. C900 – Standard for Polyvinyl Chloride (PVC) Pressure Pipe and

Fabricated Fittings, 4-12 in. (100 mm-300 mm) for Water Distribution f. C905 – Standard for Polyvinyl Chloride (PVC) Pressure Pipe and

Fabricated Fittings, 14-48 in. (350 mm-1,200 mm) g. C907 – Standard for Injection-Molded Polyvinyl Chloride (PVC)

Pressure Fittings, 4 in. Through 12 in. (100 mm Through 300 mm) 2. ASTM International, Inc. (ASTM):

a. D1785 – Specification for Poly(Vinyl Chloride)(PVC) Plastic Pipe, Schedule 40, 80, and 120

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b. D2241 – Specification for Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series)

c. D2466 – Specification for Poly(Vinyl Chloride)(PVC) Plastic Pipe Fittings, Schedule 40

d. D2467 – Specification for Poly(Vinyl Chloride)(PVC) Plastic Pipe Fittings, Schedule 80

e. D2564 – Specifications for Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Piping Systems

f. D2846 – Specifications for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic and Hot- and Cold-water Distribution Systems

g. D3034 – Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and fittings

h. F437 – Specification for Threaded Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80

i. F438 – Specification for Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Fittings, Schedule 40

j. F439 – Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Fittings, Schedule 80

k. F441 – Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedule 40 and 80

l. F442 - Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe (SDR-PR)

m. F477 – Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe

n. F679 – Specification for Poly(Vinyl Chloride)(PVC) Large-Diameter Gravity Sewer Pipe and Fittings

o. F794 – Specification for Poly(Vinyl Chloride)(PVC) Profile Gravity Sewer Pipe and Fittings Based on Controlled Inside Diameter

p. F949 – Standard Specification for Poly(Vinyl Chloride) (PVC) Corrugated Sewer Pipe With a Smooth Interior and Fittings

q. F1803 – Standard Specification for Poly(Vinyl Chloride) (PVC) Closed Profile Gravity Pipe and Fittings Based on Controlled Inside Diameter

r. D2321 – Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications

s. F891 - Specification for Coextruded Poly(Vinyl Chloride)(PVC) Plastic Pipe With a Cellular Core

t. F493 – Specification for Solvent Cements for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe and Fittings

u. F1417 – Test Method for Installation Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air

v. F1668 – Guide for Construction Procedures for Buried Plastic Pipe w. F1674 – Test Method for Joint Restraint Products Used With PVC Pipe.

3. National Science Foundation (NSF): a. NSF/ANSI 61 – Drinking Water Systems Components – Health Effects


A. Comply with the manufacturer’s handling and storage recommendations.

B. Pipes that are stored outside long-term (greater than 6 months), shall be covered with UV resistant, opaque material such that no part of any pipe to be installed is exposed to the outside elements.

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C. All pipe and fittings shall be stored on blocking, at least 4 inches off the ground and shall be kept free of debris and dirt until installation.

PART 2 - PRODUCTS

2.1 PVC PIPE AND FITTINGS, 4 THROUGH 12 INCH, PRESSURE

A. PVC Pressure Pipe: AWWA C900, DR25 Class 165, DR18 Class 235, and/or DR14 Class 305 (as shown on Drawings or in Pipe Schedule), with bell end with gasket, and with spigot end.

1. Comply with UL 1285 for fire-service mains if indicated. 2. PVC Fabricated Fittings: AWWA C900, with bell-and-spigot or double-bell

ends. Include elastomeric gasket in each bell. 3. PVC Molded Fittings: AWWA C907, pressure rating to be equal to or greater

than the pipe, with bell-and-spigot or double-bell ends. Include elastomeric gasket in each bell.

4. Push-on-Joint, Ductile-Iron Fittings: AWWA C110, ductile- or gray-iron standard pattern or AWWA C153, ductile-iron compact pattern. a. Gaskets: AWWA C111, rubber.

5. Mechanical-Joint, Ductile-Iron Fittings: AWWA C110, ductile- or gray-iron standard pattern or AWWA C153, ductile-iron compact pattern. a. Glands, Gaskets, and Bolts: AWWA C111, ductile- or gray-iron glands,

rubber gaskets, and steel bolts. 6. Victaulic fittings and joints are acceptable where specified on the drawings.

2.2 PVC PIPE AND FITTINGS, 14 THROUGH 48 INCH, PRESSURE

A. PVC Pressure Pipe: AWWA C905, DR25 Class 165, DR21 Class 200, and/or DR18 Class 235 (as shown on Drawings or in Pipe Schedule), with bell end with gasket, and with spigot end.

1. PVC Fabricated Fittings: AWWA C905, with bell-and-spigot or double-bell ends. Include elastomeric gasket in each bell.

2. Push-on-Joint, Ductile-Iron Fittings: AWWA C110, ductile- or gray-iron standard pattern or AWWA C153, ductile-iron compact pattern. a. Gaskets: AWWA C111, rubber.

3. Mechanical-Joint, Ductile-Iron Fittings: AWWA C110, ductile- or gray-iron standard pattern or AWWA C153, ductile-iron compact pattern.

4. Glands, Gaskets, and Bolts: AWWA C111, ductile- or gray-iron glands, rubber gaskets, and steel bolts.

2.3 CPVC/PVC PIPE AND FITTINGS, 6-INCH AND SMALLER, PRESSURE

A. PVC Pipe and Fittings: ASTM D 1785, Schedule 40 and Schedule 80 pipe, with plain ends for solvent-cemented joints or threaded ends conforming to ASTM D 2466, Schedule 40 or ASTM D 2467, Schedule 80, socket-type or threaded fittings. Use Schedule 80 for all pipes to be threaded. Refer to piping schedule in Section 15015 for piping connections.

B. CPVC Pipe and Fittings: ASTM F441, Schedule 40 and Schedule 80 pipe, with plain ends for solvent-cemented joints or threaded ends conforming to ASTM F438, Schedule 40 or ASTM F439, Schedule 80, socket-type or threaded fittings. Use Schedule 80 for all pipes to be threaded.

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C. Solvent Cement: As recommended by the pipe and fitting manufacturer conforming to D2564 for PVC piping systems and ASTM F493 for CPVC piping systems.

2.4 PVC PIPE AND FITTINGS, GRAVITY SEWER AND DRAIN

A. PVC Cellular-Core Pipe and Fittings: ASTM F 891, Sewer and Drain Series, PS 50 minimum stiffness pipe with ASTM D 3034, SDR 35, socket-type fittings for solvent-cemented joints.

B. PVC Sewer Pipe and Fittings, NPS 15 and Smaller: ASTM D 3034, SDR 35, with bell-and-spigot ends for gasketed joints with ASTM F 477, elastomeric seals.

C. PVC Sewer Pipe and Fittings, NPS 18 and Larger: ASTM F 679, Pipe Stiffness 46, with bell-and-spigot ends for gasketed joints with ASTM F 477, elastomeric seals.

D. PVC Profile Gravity Sewer Pipe and Fittings: ASTM F 794 - Standard Specification for Poly(Vinyl Chloride) (PVC) Profile Gravity Sewer Pipe and Fittings Based on Controlled Inside Diameter

E. PVC Profile Gravity Sewer Pipe and Fittings: ASTM F949 - Standard Specification for Poly(Vinyl Chloride) (PVC) Corrugated Sewer Pipe With a Smooth Interior and Fittings

F. PVC Profile Gravity Sewer Pipe and Fittings: ASTM F1803 - Standard Specification for Poly(Vinyl Chloride) (PVC) Closed Profile Gravity Pipe and Fittings Based on Controlled Inside Diameter

2.5 JOINING MATERIALS

A. Refer to Section 15015 "Piping Systems - Basic Materials and Methods" for commonly used joining materials.

B. Plastic Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping system manufacturer, unless otherwise indicated.

2.6 PIPING SPECIALTIES

A. Transition Fittings: Manufactured fitting or coupling same size as, with pressure rating at least equal to and ends compatible with, piping to be joined.

B. Tubular-Sleeve Pipe Couplings: 1. Description: Metal, bolted, sleeve-type, reducing or transition coupling, with

center sleeve, gaskets, end rings, and bolt fasteners and with ends of same sizes as piping to be joined. a. Standard: AWWA C219.

2.7 CORROSION-PROTECTION PIPE FITTINGS ENCASEMENT

A. Encasement for Underground Metal Pipe Fittings: ASTM A 674 or AWWA C105. 1. Form: Sheet or tube. 2. Material: LLDPE film of 0.008-inch minimum thickness or high-density, cross-

laminated PE film of 0.004-inch minimum thickness. 3. Color: Black.

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PART 3 - EXECUTION

3.1 INSTALLATION, CLEANING, AND TESTING

A. Comply with the requirements of Section 15015 “Piping Systems – Basic Materials and Methods.”

B. Testing shall be per Section 15070 “Field Testing of Piping Systems.”

3.2 PIPING SCHEDULE

A. As shown on the Drawings or in Section 15015 “Piping Systems – Basic Materials and Methods.”

END OF SECTION

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HANGERS AND SUPPORTS FOR PIPING SYSTEMS F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15060 HANGERS AND SUPPORTS FOR PIPING SYSTEMS.DOC

SECTION 15060 HANGERS AND SUPPORTS FOR PIPING SYSTEMS

PART 1 - GENERAL



1.2 SUMMARY

A. Work covered under this Section consists of providing hangers and supports for equipment and piping systems.

B. Related Sections: 1. Section 05500 “Metal Fabrications” for materials for attaching hangers and supports to

structures and buildings.

1.3 DEFINITIONS AND REFERENCES

A. Definition: 1. Wetted or Submerged: Submerged, less than one foot above liquid, below top of

channel wall, under cover or slab of channel or tank, or in other damp locations.

B. References: 1. American Welding Society (AWS):

a. D1.1 – Structural Welding Code-Steel b. D1.2 - Structural Welding Code-Aluminum c. D1.6 - Structural Welding Code-Stainless Steel

2. American Society of Mechanical Engineers: a. B31.9-Standard Building Services Piping b. Section IX, Boiler and Pressure Vessel Code: Welding and Brazing

Qualifications 3. ASTM International (ASTM):

a. B 633 – Specification for Electrodeposited Coatings of Zinc on Iron and Steel b. A 36-Standard Specifications for Carbon Structural Steel c. A 123 – Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel

Products d. A 183 – Specification for Carbon Steel Track Bolts and Nuts e. A 525 – Specification for General Requirements for Steel Sheet, Zinc-Coated

(Galvanized) by the Hot-Dip Process. f. A 653 – Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron

Alloy-Coated (Galvannealed) by the Hot-Dip Process. g. A 780 – Practice for Repair of Damaged and Uncoated Areas of Hot-Dip

galvanized Coatings. h. A 1011 – Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon,

Structural, high-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

i. C 1107 – Specification for Packaged Dry Hydraulic Cement (Non-Shrink) j. F 844 –Specification for Washers, Steel, Plain (Flat), Unhardened for General

Use Only 4. Manufacturers Standardization Society (MSS):

a. SP-58 Pipe Hangers and Supports-Materials, Design and Maintenance b. SP-69 Pipe Hangers and Supports-Selection and Application c. SP-89 Pipe Hangers and Supports-Fabrication and Installation Practices d. SP-127 Bracing for Piping Systems Seismic-Wind-Dynamic Design, Selection,

Application 5. NFPA (National Fire Protection Association):

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a. NFPA 13 – Standard for the Installation of Sprinkler Systems b. NFPA-14 - Standard for the Installation of Standpipes and Hose Systems c. NFPA 70 - National Electrical Code

1.4 SUBMITTALS

A. Product Data: 1. Product data to include, but not be limited to materials, finishes, testing agency

approvals, load ratings, and dimensional information. 2. Provide installation instructions for each type of hanger and support. 3. Submit pipe hanger and support schedule showing manufacturer's Figure No., size,

location, and features for each required pipe hanger and support.

B. Shop Drawings: Provide for each type of hanger and support, indicating dimensions, weights, required clearances, and methods of component assembly. Indicate all loads exceeding 250 lbs imposed on building support systems and on structures.

C. Informational Submittals: 1. Welder certificates signed by Contractor certifying that welders comply with

requirements specified under the "Quality Assurance" Article. 2. Product certificates signed by manufacturer certifying that their product meet the

specified requirements.


A. Welding: 1. Qualify welding processes and welding operators according to the following codes

depending on the material welded. a. AWS D1.1 "Structural Welding Code--Steel." b. AWS D1.2 "Structural Welding Code-Aluminum.” c. AWS D1.6 "Structural Welding Code-Stainless Steel.”

2. Certify that each welder has satisfactorily passed AWS qualification tests for welding processes involved and, if pertinent, has undergone recertification.

B. Qualify welding processes and welding operators according to ASME "Boiler and Pressure Vessel Code," Section IX, "Welding and Brazing Qualifications."

C. NFPA Compliance: Comply with NFPA 13 for hangers and supports used as components of fire protection systems.

D. Listing and Labeling: Provide hangers and supports that are listed and labeled as defined in NFPA 70, Article 100. 1. UL and FM Compliance: Hangers, supports, and components include listing and

labeling by UL and FM where used for fire protection piping systems. 2. Listing and Labeling Agency Qualifications: A “Nationally Recognized Testing

Laboratory” (NRTL) as defined in OSHA Regulation 1910.7.

E. Licensed Operators: Use operators that are licensed by powder-operated tool manufacturers to operate their tools and fasteners.


A. Engineered Hanger and Support System: The CONTRACTOR shall provide an engineered hanger and support system for the various piping systems indicted on the Drawings. This includes the design of multiple piping supports and trapeze hangers and the selection of appropriate hangers and anchors to the structures, buildings, and facilities. This design shall be accomplished by a professional engineer license in the state where the Project is to be constructed.

B. Codes and Standards: 1. Regulatory Requirements: Comply with applicable plumbing codes pertaining to

product materials and installation of the hanger and support system.

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2. NFPA Compliance: Hanger and support system shall comply with NFPA -13 when used as a component of a fire protection system and NFPA-14 when used as a component of a standpipe system.

3. UL and FM Compliance: Hanger and support system components shall be listed and labeled by UL and FM when used for fire protection systems.

4. National Recognized Testing Laboratory and NEMA Compliance (NRTL): Instead of UL and FN compliance, the hanger and support system components shall be listed and labeled by a NTRL where used for fire protection systems. The term “NTRL” shall be as defined in OSHA Regulation 1910.7.

5. Duct Hangers: SMACNA Duct Manuals. 6. MSS Standard Compliance: Provide hanger and support system components of which

materials, design, and manufacture comply with MSS SP-69.

C. Design Requirements: 1. General:

a. The configuration and layout of yard and station piping systems are shown in the Drawings.

b. In certain locations, pipe supports, anchors, and expansion joints have been indicated on the drawings, but no attempt has been made to indicate every pipe support, anchor, and expansion joint.

c. It shall be the CONTRACTOR'S responsibility to provide a complete system of pipe supports, to provide expansion joints, and to provide restraints and anchor all piping, in accordance with the requirements set forth herein.

d. Additional pipe supports may be required adjacent to expansion joints, couplings, flanged connections, or valves.

e. Piping Smaller than 30-inches: Supports are shown only where specific types and locations are required; provide additional pipe, valve, and equipment supports as required.

f. Piping 30-inches and Larger: Support systems have been designed for piping and shall be placed at the designated locations as shown on the Drawings

g. Comply with the requirements of MSS SP-58, MSS SP-69, and MSS SP-89. 2. Piping Support Systems:

a. Support Load: Dead loads imposed by weight of pipes filled with water, except air and gas pipes, plus insulation.

b. Safety Factor: Minimum of 5. c. Maximum Support Spacing and Minimum Rod Size:

1) Steel or Ductile Iron Piping:

Table 1 Steel or Ductile Iron Pipe

Pipe Size Maximum Support/Hanger

Spacing Minimum Rod Size

Single Rod Hangers 1-inch and smaller 6 feet 1/4-inch 1-1/2-inch thru 2-1/2-inch 8 feet 1/4-inch

3-inch & 4-inch 10 feet 3/8-inch 6-inch 12 feet 3/8-inch 8-inch 12 feet 1/2-inch 10-inch & 12-inch 14 feet 5/8-inch 14-inch 16 feet 3/4-inch 16-inch & 18-inch 16 feet 7/8-inch 20-inch 18 feet 1-inch 24-inch 18 feet 1-1/4-inch 30-inch and larger As shown on Drawings As shown on Drawings

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2) Copper Piping: a) Maximum Support Spacing: Two (2) feet less per size than listed

for steel, with 1-inch and smaller pipe supported every five (5) feet. b) Minimum Hanger Rod Size: Same as listed for steel pipe.

3) Plastic and Fiberglass Piping: a) Maximum Support Spacing: As recommended by manufacturer for

flow and temperature in pipe. b) Minimum Rod Sizing: Same as listed for steel pipe. c) Provide supports with width as required by pipe manufacturer and

shields as required to protect pipe in accordance with manufacturer’s requirements.

4) Stainless Steel Piping:

Table 2 Stainless Steel Pipe

Pipe Size Maximum Support/Hanger

spacing Minimum Rod Size

Single Rod Hangers 1-inch thru 4-inch 8 feet 1/4-inch 6-inch 8 feet 3/8-inch 8-inch & 10-inch 10 feet 1/2-inch 12-inch 10 feet 1/2-inch 14-inch & 16-inch 12 feet 5/8-inch 18-inch & 20-inch 14 feet ¾-inch 24-inch 14 feet 7/8-inch

3. Framing Support Systems:

a. Beams: Size such that beam stress does not exceed 25,000 psi and maximum deflection does not exceed 1/240 of span.

b. Column Members: Size in accordance with manufacturer’s recommended method.

c. Support Loads: Calculate using weight of pipes filled with water. d. Maximum Spans:

1) Steel and Ductile Iron Pipe, 3-Inch Diameter and Larger: 10-foot centers, unless otherwise shown.

2) Other Pipelines and Special Situations: May require supplementary hangers and supports.

e. Electrical Conduit Support: Include in design of framing support systems. 4. Anchoring Devices: Design, size, and pace support devices, including anchor bolts,

inserts, and other devices used to anchor support, to withstand shear and pullout loads imposed by loading and spacing on each particular support.

5. Vertical Sway Bracing: 10-foot maximum centers, or as shown. 6. Existing Support Systems: use existing support systems to support new piping only if

CONTRACTOR can show that they are adequate for the additional loads, or if they are strengthened to support the additional load.

1.7 PRODUCT DELIVERY, STORATE AND HANDLING

A. Comply with the manufacturer's recommendations and Section 01600 “Product Requirements.”

PART 2 - PRODUCTS

2.1 MANUFACTURED UNITS

A. General: 1. When specified items are not available, fabricate pipe supports of correct material and

to general configuration indicated in catalogs.

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2. Special supports and hangers details will be required for cases where standard catalog supports are inapplicable.

3. Materials: Unless otherwise shown on the Drawings, fabricate supports using the following materials: a. Wetted and Submerged: Type 316 Stainless Steel. b. Atmospheric Exposed: Hot-dipped galvanize after fabrication, coat in

accordance with Section 09910 “Painting and Protective Coatings.” c. Hardware: Type 316 Stainless Steel.

B. Hangers, Supports, and Components: 1. Selection and application of pipe hangers and supports for all service temperatures

shall be in accordance with MSS SP-69. 2. Requirements for material, design and manufacture of standard types of hanger and

support system components shall be in accordance with MSS SP-58. 3. Requirements for the fabrication and installation of the hanger and support system

shall be in accordance with MSS SP-89. 4. Requirements relating to the design, selection, and applications of bracing for piping

systems subject to seismic-wind-dynamic loading shall be in accordance with MSS SP-127.

5. Components include galvanized coatings where installed for piping and equipment that will not have a field-applied finish.

6. Pipe attachments shall include a nonmetallic coating for electrolytic protection where attachments are in direct contact with copper pipe and tubing.

C. Products: 1. Available Products: Subject to compliance with requirements, products that may be

incorporated into the Work include, but are not limited to, the following: a. ANVIL International, Inc. b. Cooper B-Line, Inc. c. National Pipe Hanger Corporation d. Piping Technology & Products, Inc.

2.2 HANGERS

A. Adjustable Clevis Hanger: MSS SP-58, Type 1.

B. Adjustable Swivel Ring for Non-Insulated Pipe: MSS Type 7.

C. Hinged Split-Ring Pipe Clamp: MSS SP-58, Type 6 or 12.

D. Yoke and Roller Hanger: MSS Type 41 and 43.

E. U-Bolts: MSS Type 24.

F. Straps: Mss Type 26.

G. Anchor Rods, Clevises, Nuts, Sockets, and Turnbuckles: In accordance with MSS SP-58.

H. Attachments: 1. I-Beam Clamp: Concentric loading type, MSS SP-58, Type 21, 28, 29, or 30, which

engage both sides of flange. 2. Concrete Insert: MSS SP-58, Type 18, continuous channel insert with load rating not

less than that of hanger rod it supports.

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2.3 PIPE SUPPORTS

A. Pedestal Type: Schedule 40 pipe stanchion, saddle, and anchoring flange. 1. Nonadjustable Saddle: MSS SP-58, Type 37 with U-bolt. 2. Adjustable Saddle: MSS SP-58, Type 38 without clamp.

B. Pipe Stanchion: Anvil Figure 62 and 63 for support of steel pipe elbows, horizontal pipe, and for use with pipe saddles.

2.4 ROLLERS AND ROLLER SUPPORTS

A. Roller with Adjustable Support Stand: 1. Designed for pipe support where longitudinal movement and vertical adjustment is

required. 2. Non-metallic roller with stainless steel stand and hardware. 3. Complies with MSS SP-69 and SP-58, Type 46.

B. Roller with Non-Adjustable Support Stand: 1. Designed for supporting pipe with longitudinal movement. 2. Non-metallic roller with stainless steel chair, stand and hardware. 3. Complies with MSS SP-69 and SP-58, Type 44.

C. Roller with Ceiling Suspended Supports: 1. Designed for suspending pipe where longitudinal movement and vertical adjustment is

required. 2. Steel with cast iron roller, standard finish. 3. Complies with MSS SP-69 and SP-58, Type 43 or Type 41.

2.5 WALL SUPPORTS

A. Horizontal Pipe: 1. 1/4-Inch Thru 4-Inches: Offset or straight J-hook. 2. 4-Inches and Greater: Welded steel bracket MSS Type 31, 32, or 33 and wrought

steel clamp. Provide adjustable steel yoke and cast iron roll MSS Type 44 for hot pipe 2000 F and over and for sizes 6-inches and greater.

B. One-Hole Clamp: Anvil; Figure 126.

C. Channel Type: Unistrut, Anvil, Cooper B-Line.

2.6 PIPE CLAMPS

A. Riser Clamp: MSS SP-58, Type 4.

B. Flexibility in hanger assembly required due to horizontal movement, use pipe clamps with weldless eye nuts: MSS SP-58, Type 4, with Type 17. For insulated lines use double bolted pipe clamps: MSS SP-58, Type 3, with Type 17.

C. Offset Pipe Clamp: Galvanized carbon steel clamp for use is supporting piping away from floor or wall; Anvil Figure 103 or equivalent.

D. Extension Pipe or Riser Clamp: Galvanized carbon steel riser clamp for support of vertical piping complying with MSS SP-69 and MSS-58, Type 8 and Type 42. Type 42 is designed also to be supported by hanger rods.

2.7 MULTIPLE OR TRAPEZE HANGERS

A. Trapeze hangers constructed from 12 gauge roll formed ASTM A1011 SS Gr. 33 structural steel channel, 1-5/8-inch x 1-5/8-inch minimum.

B. Mount pipes to trapeze with two piece pipe straps sized for outside diameter of pipe.

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C. Pipes subject to axial movement: 1. Use strut mounted roller supports; use pipe protection shield or saddles on FRP and

insulated lines. 2. Use strut mounted pipe guide as required.

2.8 CHANNEL TYPE SUPPORT SYSTEMS

A. Steel Construction: 1. Channel: Pre-galvanized in accordance with ASTM A525, Class G90, or hot-dip after

fabrication. 2. Hardware: Type 316 stainless steel. 3. Channel Size:

a. Single Channel: 14-gauge, 1-5/8” by 1-5/8”. b. Double Channel: 14-gauge, 3-1/4” by 1-5/8”. c. Manufacturer: Unistrut Series P1000 or equivalent.

4. Members and Connections: MFMA-2, factory-fabricated components for field assembly. Design for all loads with Safety Factor of 5.

5. Pipe and Tubing Clamps: Unistrut “Cush-A-Clamp” Omega Series or U-Bolt Series, stainless steel construction with thermoplastic elastomer cushion or equivalent.

B. Fiberglass Construction: 1. Channel: Polyester and vinylester reinforce with multiple strands of glass filament, UV

resistant surfacing veils channels. a. Single Channel: Heavy duty 1-5/8’” by 1-5/8”; Unistrut Series F20V-2000. b. Double Channel: Heavy duty 3-1/4” by 1-5/8”; Unistrut Series F20V-2100.

2. Seal all cut ends with a clear sealer and provide end caps on exposed ends after assembly.

3. Hardware: Fiberglass or stainless steel.

C. Available Manufactures: 1. Anvil; Power-Strut Line 2. Cooper B-Line 3. National Pipe Hangers Corporation 4. Unistrut Corporation

2.9 ACCESSORIES

A. Protection Shields: MSS Type 40; galvanized steel or stainless steel, 180 degrees arc, minimum 12-inches long, to prevent crushing insulation.

B. Protection Saddles: MSS Type 39; fill interior with segments of insulation matching adjoining insulation.

C. Thermal Shields: 1. Provide 100-psi minimum compressive strength, waterproof, asbestos free calcium

silicate, encased with a sheet metal enclosure. Insert and shield shall cover the entire circumference or the bottom half circumference of the pipe, with length recommended by the manufacturer for pipe size and thickness of insulation.

2. Cold Piping: Calcium silicate shall extend beyond the sheet metal shield allowing overlap of vapor barrier.

3. Piping, 4-inches and larger, supported on trapeze or pipe rollers, provide double thickness shields.

4. Piping, 12-inches and greater, provide 600 psi calcium silicate structural insert.

D. Vibration Isolation and Supports: 1. For refrigeration, air conditionings, hydraulic, pneumatic, and other vibrating system

applications, use a clamp that has a vibration dampening inserts and a nylon inserted locknut. For copper and steel tubing use Cooper B-Line BVT series VibraClamps, for pipe sizes use BVP series, or equivalent.

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2. For larger tubing or piping subjected to vibration, use neoprene or spring hangers as required. For spring hangers use Mason or equal.

3. For base mounted equipment use vibration pads, molded neoprene mounts, or spring mounts as required.

4. Vibration isolation products as manufactured by Cooper B-Line, VibraTrol systems, or equivalent.

E. Intermediate Pipe Guides: 1. Piping, 6-inches and smaller:

a. Type: Pipe clamp with oversized pipe sleeve to provide minimum 1/8-inch clearance.

2. Piping, 8-inches and larger: a. Type: Specially formed U-bolts with double nuts to provide 1/4-inch minimum

clearance around pipe. b. U-Bolt Stock Size:

1) 8-inch Pipe: 5/8-inch 2) 10-inch Pipe: 3/4-inch 3) 12-inch through 16-inch Pipe: 7/8-inch 4) 18-inch through 30-inch Pipe: 1-inch

F. Pipe Alignment Guides: 1. Piping 8-inches and Smaller: Spider of sleeve type. 2. Piping 10-inches and Larger: Roller type.

G. Pipe Anchors: 1. Type: Anchor chair with U-bolt.

H. Hangers shall be threaded at either end or continuous threaded rods of circular cross section. Use adjusting locknuts at upper attachments and hangers. No wire, chain, or perforated straps are allowed.

2.10 MISCELLANEOUS MATERIALS

A. Hanger Support Anchors: Comply with the requirements of Section 05501 “Anchor Bolts and Concrete Inserts” for cast-in-place anchors, concrete and masonry drilled anchors, and material of construction for anchors based on the environment. 1. Insert-type attachments with pull-out and shear capacities appropriate for supported

loads and building materials where used. Fasteners for fire protection systems include UL listing and FM approval.

B. Powder actuated fasteners and other types of bolts and fasteners not specified herein shall not be used unless approved by ENGINEER. 1. Powder-actuated-type, drive-pin attachments with pull-out and shear capacities

appropriate for supported loads and building materials where used. Fasteners for fire protection systems include UL listing and FM approval.

C. Structural Steel: ASTM A 36/A 36M, steel plates, shapes, and bars, black and galvanized.

D. Bolts and Nuts: ASME B18.10 or ASTM A 183, steel, hex-head, track bolts and nuts.

E. Washers: ASTM F 844, steel, plain, flat washers.

F. Grout: ASTM C 1107, Grade B, nonshrink and nonmetallic; 1. Characteristics include post-hardening, volume-adjusting, dry, hydraulic-cement-type

grout that is nonstaining, noncorrosive, nongaseous and is recommended for both interior and exterior applications.

2. Design Mix: 5000-psi, 28-day compressive strength. 3. Water: Potable. 4. Packaging: Premixed and factory-packaged.

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PART 3 - EXECUTION

3.1 PREPARATION

A. Examine areas and conditions under which the hanger and support system will be installed. Do not proceed with work until satisfactorily conditions have been corrected in manner acceptable to installer.

B. Proceed with installation of the hanger and support system only after required structural work has been completed in areas where work is to be installed. Correct inadequacies including, but not limited to. Proper placement of inserts, anchors, and other structural attachments. Review Drawings to obtain structural support limitations.

3.2 HANGER AND SUPPORT INSTALLATION

A. General: Comply with MSS SP-69 and SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from building structure.

B. Channel Support Installation: Arrange for grouping of parallel runs of horizontal piping supported together on field-fabricated, heavy-duty trapeze hangers where possible. 1. Field assemble and install according to manufacturer’s instructions.

C. Heavy-Duty Steel Trapezes: Arrange for grouping of parallel runs of horizontal piping and support together on field-fabricate heavy-duty trapezes. 1. Pipes of Various Sizes: Support together and space trapezes for smallest pipe size or

install support intermediate supports for smaller diameter pipes as specified above for individual pipe hangers.

2. Field-fabricate from ASTM A36 steel shapes selected for loads being supported. 3. Weld steel according to AWS D-1.1.

D. Install building attachments within concrete or to structural steel. Space attachments within maximum piping span length indicated in MSS SP-69. Install additional attachments at concentrated loads, including valves, flanges, guides, strainers, expansion joints, and at changes in direction of piping. Install concrete inserts before concrete is placed; fasten insert to forms. Install reinforcing bars through openings at top of inserts.

E. Install powder-actuated drive-pin fasteners in concrete after concrete is placed and completely cured. Use operators that are licensed by powder-actuated tool manufacturer. Install fasteners according to powder-actuated tool manufacturer's operating manual. Do not use in lightweight concrete slabs or in concrete slabs less than 4 inches thick.

F. Install mechanical-anchor fasteners in concrete after concrete is placed and completely cured. Install according to fastener manufacturer's written instructions. Do not use in lightweight concrete slabs or in concrete slabs less than 4 inches thick.

G. Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers, and other accessories.

H. Support fire protection systems piping independent of other piping.

I. Install hangers and supports to allow controlled movement of piping systems, permit freedom of movement between pipe anchors, and facilitate action of expansion joints, expansion loops, expansion bends, and similar units.

J. Load Distribution: Install hangers and supports so that piping live and dead loading and stresses from movement will not be transmitted to connected equipment.

K. Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and so that maximum pipe deflections allowed by ASME B31.9 "Building Services Piping" is not exceeded.

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L. Insulated Piping: Comply with the following installation requirements. 1. Clamps: Attach clamps, including spacers (if any), to piping with clamps projecting

through insulation; do not exceed pipe stresses allowed by ASME B31.9. 2. Saddles: Install protection saddles MSS Type 39 where insulation without vapor

barrier is indicated. Fill interior voids with segments of insulation that match adjoining pipe insulation.

3. Shields: Install MSS Type 40, protective shields on cold piping with vapor barrier. Shields span an arc of 180 degrees and have dimensions in inches not less than the following:

Table 3

Shield Length and Thickness NPS

(Inches) Shield Length

(Inches) Shield Thickness

(Inches) 1/4 to 3-1/2 12 0.048

4 12 0.060 5 and 6 18 0.060 8 to 14 24 0.075 16 to 24 24 0.105

4. Pipes 8 Inches (200 mm) and Larger: Include wood inserts. 5. Insert Material: Length at least as long as the protective shield. 6. Thermal-Hanger Shields: Install with insulation of same thickness as piping.

M. Piping Support General Applications: 1. Support piping connections to equipment by pipe support and not by the equipment. 2. Support large or heavy valves, fittings, and appurtenances independently of

connected piping. 3. Do not support one pipe from another. 4. Support pipe at changes in direction or in elevation, adjacent to flexible joints and

couplings, and where shown. 5. Do not install pipe supports and hangers in equipment access areas or bridge crane

runs. 6. Brace hanging pipes against horizontal movement by both longitudinal and lateral

sway bracing. 7. Install pipe anchors where required to withstand expansion thrust loads and to direct

and control thermal expansion. 8. Repair mounting surfaces to original condition after attachments are made.

N. Standard Pipe Supports: 1. Horizontal Suspended Piping:

a. Single Pipes: Adjustable swivel-ring, split-ring, or clevis hangers. b. Grouped Pipes: Trapeze hanger systems. c. Furnished galvanized steel protection shield and oversized hangers for all

insulated pipes. d. Furnish precut sections of rigid insulation with vapor barrier at hangers for all

insulated pipe. 2. Horizontal Piping Supported from Walls:

a. Single Pipes: Wall brackets or wall clips attached to wall with anchors. Clips attached to wall mounted framing also acceptable.

b. Stacked Piping: 1) Wall mounted framing system and clips acceptable for piping smaller

than 3-inch nominal diameter. 2) Piping clamps which resist axial movement of pipe through support not

acceptable. c. Wall mounted piping clips not acceptable for insulated piping.

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3. Horizontal Piping Supported From Floors: a. Stanchion Type:

1) Pedestal type; adjustable with stanchion, saddle, and anchoring flange. 2) Use yoked saddles for piping whose centerline elevation is 18-inches or

greater above the floor and for all exterior installations. 3) Provide neoprene waffle isolation pad under anchoring flanges, adjacent

to equipment or where otherwise required to provide vibration isolation. b. Floor Mounted Channel Supports:

1) Use for piping smaller than 3-inch nominal diameter running along floors and in trenches at piping elevations lower than can be accommodated using pedestal pipe supports.

2) Attach channel framing to floors with anchor bolts. 3) Attach pipe to channel framing with clips or pipe clamps.

c. Concrete Cradles: Use for piping larger than 3-inch nominal diameter along floor and in trenches at piping elevations lower than can be accommodated using stanchion type.

4. Vertical Pipe: Support with wall brackets and base elbow or riser clamps on floor penetrations.

5. Standard Attachments: a. To Concrete Ceilings: Concrete inserts. b. To Steel beams: I-beam clamps or welded attachments. c. To Wooden Beams: Lag screws and angle clips to members with anchor bolts. d. To Concrete Walls: Concrete inserts or brackets or clip angles with anchor

bolts. 6. Existing Walls and Ceilings: Install as specified unless otherwise shown.

O. Intermediate and Pipe Alignment Guides: 1. Provide pipe alignment guides (or pipe supports that accomplishes the same function)

at all expansion joints and loops. 2. Guide piping on each side of an expansion joint or loop at four to fourteen pipe

diameters distance from each joint or loop. 3. Install intermediate guides on metal framing support systems not carrying a pipe

anchor or alignment guide.

P. Accessories: 1. Insulation Shield: Install on insulated non-steel piping. Oversized rollers and supports. 2. Welding Insulated Saddle: Install on insulated steel pipe. Oversized rollers and

supports. 3. Vibration Isolation Pad: Install under base flange of pedestal type pipe supports

adjacent to equipment, and where required to isolate vibration. 4. Dielectric Barrier:

a. Install between carbon steel members and copper or stainless steel pipe. b. Install between stainless steel supports and nonstainless steel ferrous metal

piping. 5. Electrical isolation: Install 1/4-inch by 3-inch neoprene rubber wrap between

submerged metal pipe and oversized clamps.

Q. Piping and ductwork supports are to be independent supports and directly supported from building or structure. Combining supports from more than one trade is not permitted.

3.3 EQUIPMENT SUPPORTS

A. Fabricate structural steel stands to suspend equipment from structure above or support equipment above floor.

B. Grouting: Place grout under supports for equipment, and make a smooth bearing surface.

3.4 METAL FABRICATION

A. Cut, drill, and fit miscellaneous metal fabrications for pipe and equipment supports.

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B. Fit exposed connections together to form hairline joints. Field-weld connections that cannot be shop-welded because of shipping size limitations.

C. Field Welding: Comply with AWS D1.1 procedures for manual shielded metal-arc welding, appearance and quality of welds, methods used in correcting welding work, and the following: 1. Use materials and methods that minimize distortion and develop strength and

corrosion resistance of base metals. 2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. Finish welds at exposed connections so that no roughness shows after finishing, and

so that contours of welded surfaces match adjacent contours.

3.5 ADJUSTING

A. Hanger Adjustment: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe.

3.6 PAINTING

A. Touching Up: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint on miscellaneous metal is specified in Section 09910 “Painting and Protective Coatings.”

B. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply galvanizing-repair paint to comply with ASTM A780.

3.7 VIBRATION

A. Vibration of the piping system during operation is not acceptable.

B. CONTRACTOR shall provide additional lateral supports as required to eliminate piping vibration at no addition cost to OWNER.

END OF SECTION

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VALVES, BASIC REQUIREMENTS AND MISCELLANEOUS F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15100 VALVES, BASIC REQUIREMENTS AND MISCELLANEOUS.DOC

SECTION 15100 VALVES, BASIC REQUIREMENTS AND MISCELLANEOUS

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the following general-duty valves: 1. Ball Valves, Bronze, 2-1/2 inches and smaller. 2. Ball Valves, Ferrous-Alloy, 2-1/2 inches and smaller. 3. Ball Valves, PVC, 6-inches and smaller. 4. Ball Valves, Stainless Steel, 12-inches and smaller. 5. Check Valves, PVC, 4 inches and smaller. 6. Reduced Pressure Backflow Preventer Assembly, 2-1/2 inches to 10-inches 7. Diaphragm Valves, CPVC 8. Flap Gate, Cast Iron 9. Valve appurtenances.

B. Related Sections: 1. Refer to Section 15015 “Piping System, Basic Materials and Methods” for information

regarding correlation with piping system submittals; coordination; material delivery, handling, and storage; projection conditions; design requirements; other materials; installation of piping systems; field testing; and related work.

2. Refer to Section 15101 “Valves, Gate” for AWWA gate valves, 3-inch and larger, and for iron body gate valves, 3 inches through 24 inches.

3. Refer to Section 15104 “Valves, Check” for AWWA swing check valves, 2-inch through 36 inches, iron body swing check valves, 2 inches through 12 inches, double-disc check valves, 2 inches through 36 inches, rubber flapper check valves, 2 inches through 36 inches, iron body ball check valve, 3 inches and larger, and “duckbill” elastomeric check valves, 2-inch through 84 inches.

4. Refer to Section 15103 “Valves, Plug” for eccentric plug valves.

1.3 DEFINITIONS

A. Following are standard abbreviations used for valves: 1. CWP: Cold working pressure. 2. EDPM: Ethylene-propylene-diene terpolymer rubber. 3. NRS: Nonrising stem. 4. OS&Y: Outside screw and yoke. 5. PTFE: Polytetrafluoroethylene plastic. 6. SWP: Steam working pressure. 7. WOG: Water, oil and gas (Cold working pressure) 8. TFE: Tetrafluoroethylene plastic.

1.4 SUBMITTALS

A. Product Data: For each type of valve indicated. Include body, seating, and trim materials; valve design; pressure and temperature classifications; end connections; arrangement; dimensions; and required clearances. Include list indicating valve and its application. Include rated capacities; shipping, installed, and operating weights; furnished specialties; and accessories.

B. Product Certificates: For each type of valve, from manufacturer.

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1. Compliance with AWWA, ASTM, and ANSI standards including hydrostatic tests, operational tests and other testing required by the standards.

C. Operation and Maintenance Data: Provide in accordance with Section 01782 “Operation and Maintenance Data.”

D. Field Quality Control: Provide field testing and performance reports.


A. Obtain all valves of the same style and type, along with the associated manual operators, from a single manufacturer.

B. NSF Compliance: NSF 61, “Drinking Water Systems Components – Health Effects” for valve materials for potable-water service.

C. Valve manufacturer shall demonstrate a minimum of five years of experience is similar applications for size of valves furnished. References shall be provided upon request.

D. Valve supplier shall maintain a complete stock of parts in the state where the Project is constructed or shall indicate that parts will be delivered upon 48-hour after receipt of request.


A. Prepare valves for shipping as follows: 1. Protect internal parts against rust and corrosion. 2. Protect threads, flange faces, grooves, and weld ends. 3. Set angle, gate, and globe valves closed to prevent rattling. 4. Set ball and plug valves open to minimize exposure of functional surfaces. 5. Set butterfly valves closed or slightly open. 6. Block valves in either closed or open position.

B. Use the following precautions during storage: 1. Maintain valve end protection. 2. Store valves indoors and maintain at higher than ambient dew-point temperature. If

outdoor storage is necessary, store valves off the ground in watertight enclosures. 3. Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not

use handwheels or stems as lifting or rigging points.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Available Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, those listed in the valve descriptions.

2.2 GENERAL

A. Valve to include operator, actuator, handwheel, chain wheel, extension stem, floor stand, worm and gear operator, operating nut, chain, wrench, valve boxes, and all accessories and related equipment for a complete operating system. Refer to P&ID Drawings for valves requiring limit switches, electric or pneumatic operators, and related controls.

B. Comply with the following: 1. Service: Suitable for intended service, with valve pressure and temperature ratings

not less than indicated and as required for the system pressures and temperatures. 2. Valve Sizes: Same size as connection to upstream piping, unless otherwise

indicated. 3. Valve Ends (Unless otherwise specified):

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a. Compatible with adjacent piping or equipment connections. b. Bronze Valves: 2-inch and Smaller; threaded or soldered ends depending on

application. c. Ferrous valves, 3-inch and Smaller: Threaded ends. d. Ferrous Valves, 3-inch and Larger:

1) Exposed Valves: Flanged ends. 2) Buried Valves: Mechanical joint ends.

C. Valves 1. Pressure Reducing: Provide a spring-loaded valve, with semi-steel body and

stainless steel inner valve, disc seat and disc spring, adjusting spring of corrosion-resistance steel and synthetic composition diaphragm, such as Fischer 630.

2. Pressure Relief: Furnish spring-loaded, bronze body relief valves with enclosed spring. Use seats specially ground for compressed air service, Crosby Type AC with trip lever.

3. Gate Valves: For 2-1/2 inch and smaller, provide 150-lb solid disc, union bonnet, rising stem gate valves.

4. Ball Valves: For 3 inch and smaller, provide ferrous alloy ball valve conforming to the requirements of Section 15100 “Valves, Basic Requirements and Miscellaneous.”

5. Check Valves: For 2 inches and smaller provide 300-lb bronze, Stockham B-634 or Jenkins 962A. For 2-1/2 inches and 3 inches, provide non-slam wafer type, Mission Duo-Check, Style K.

D. Valve Actuators: 1. Operator sized to operate valve for full range of pressures and velocities. 2. Open by turning counterclockwise, clockwise to close, unless otherwise specified. 3. Chainwheel: For attachment to valves, of size and mounting height, as indicated in

the "Valve Installation" Article in Part 3. 4. Gear Drive Operator: For quarter-turn valves 8-inch and larger. 5. Handwheel: For valves other than quarter-turn types. 6. Lever Handle: For quarter-turn valves 6-inch and smaller. 7. Wrench: For valves with square heads. Furnish OWNER with one wrench for every

10 valves, for each size square plug head.

E. Valves in Insulated Piping: Valves shall have 2-inch stem extensions and the following features: 1. Gate Valves: Shall be rising-stem type. 2. Ball Valves: Shall have extended operating handle of non-thermal-conductive

material, protective sleeve that allows operation of valve without breaking the vapor seal or disturbing insulation, and memory stops that are fully adjustable after insulation is applied.

3. Butterfly Valves: Shall have extended necks.

F. Valve Flanges: ASME B16.1 for cast-iron valves, ASME B16.5 for steel valves and ASME B16.24 for bronze valves.

G. Valve Grooved Ends: AWWA C606.

H. Solder Joint: With sockets according to ASME B16.18. 1. Caution: Use solder with melting point below 840 deg F for angle, check, gate, and

globe valves; below 421 deg F for ball valves.

I. Threaded: With threads according to ASME B1.20.1.

J. Valve Bypass and Drain Connections: MSS SP-45.

K. Factory assemble valve with operator, actuator and accessories.

L. Fasteners for flanged valves shall be as follows: Comply with pipe joining material requirements of Section 15015 “Piping Systems, Basic Materials and Methods.”

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M. Obtain all valves of the same type and materials of construction with associated manual operators from a single manufacturer

2.3 MATERIALS

A. Brass and bronze valve components and accessories shall be made with dezincification-resistant materials. Bronze valves made with copper alloy (brass) containing more than 15 percent zinc are not permitted.

B. Approved alloys are of the following ASTM designations: 1. B61, B62, B98 (Alloy No. C65100, C65500, or C66100), B127, B139 (Alloy No.

C51000), B584 (Alloy UNS No. C90300 or C94700), B164, and B194. 2. Stainless steel, ANSI Type 316 may be substituted for bronze.

2.4 FACTORY FINISHING

A. Interior Lining and Coating: 1. Interior ferrous metal surfaces of valve body, stem, actuator and related components

shall be epoxy coated in accordance with AWWA C550 “Protective Epoxy Interior Coatings for valves and Hydrants”, unless otherwise specified.

2. Epoxy coating material shall be NSF approved for use in potable water. 3. Either two-part liquid material or heat-activated (fusion) material except only heat-

activated material if specified as “fusion” or “fusion bonded” epoxy. 4. Color to match adjacent piping. Coating application to be accomplished in

accordance with Section 09910 “Painting and Protective Coatings.” 5. Safety isolation and lockout valves with handles, handwheels, or chain wheels

“Safety Yellow.” 6. Exposed valves, other than above, paint handles, handwheels, or chain wheels

“Red.” 7. Manufacturer shall apply shop primer coating on valves in the factory prior to delivery

with product described in Specification Section 09910. Contractor shall apply finish coating with product described in Specification Section 09910.

8. Manufacturer shall apply shop primer coating on bonnets in the factory prior to delivery with product described in Specification Section 09910. Contractor shall apply finish coating with product described in Specification Section 09910. Coating for submerged valves shall apply to the submerged section of the bonnet plus 1’-0” above water surface. Coatings for exterior valves shall be applied to the remaining section of the bonnet.

B. Exterior Coating 1. Manufacturer shall apply shop primer coating to valves and bonnet assemblies in the

factory prior to delivery with product described in Specification Section 09910.

2.5 BALL VALVE

A. Bronze Ball Valves, General: MSS SP-110 and have bronze body complying with ASTM B 584, except for Class 250 which shall comply with ASTM B 61, full-depth ASME B1.20.1 threaded or solder ends, and blowout-proof stems. 1. Two-Piece, Full-Port, Bronze Ball Valves with Bronze Trim: Chrome-plated bronze

ball and bronze stem and; reinforced TFE seats; threaded body packnut design (no threaded stem designs allowed) with adjustable stem packing, solder or threaded ends; and 150 psig SWP 600-psig CWP rating. a. Manufactures:

1) Crane Valve Group. 2) NIBCO. 3) Milwaukee Valve.

2. Two-Piece, Full-Port, Bronze Ball Valves with Stainless-Steel Trim: Type 316 stainless-steel vented ball and stem, reinforced TFE seats, threaded body packnut

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design (no threaded stem designs allowed) with adjustable stem packing, soldered or threaded ends; 150 psig SWP and 600-psig CWP ratings. a. Manufactures:

1) Crane Valve Group. 2) NIBCO. 3) Milwaukee Valve.

B. Ferrous-Alloy Ball Valve, 3-inch and Smaller: 1. Split-body construction, ASTM A-216 Type WCB, carbon-steel body; ASTM A-351,

Type CF8M vented stainless-steel ball; and ASTM A-276, Type 316 stainless-steel stem; carbon-filled TFE seats; 285 psig CWP rating.

2. Fire rated according to API 607 (4th edition); and having flanged ends and blowout-proof stem.

3. Conforms to MSS SP-72. 4. Manufactures:

a. Crane Valve Group. b. NIBCO. c. Milwaukee Valve.

C. PVC/CPVC Ball Valve, 2-inches and Smaller: 1. True union type manufactured to ATSM F 1970 and constructed from PVC Type 1,

ASTM D 1784 Cell Classification 12454 or CPVC Type IV, ASTM D 1784 Cell Classification 23447; O-rings shall be EDPM or Viton®; ball seats of PTFE; handles of polypropylene; supplied with solvent-welded or threaded ends; approved for potable water service; rated at 150 psi at73oF; and shall be full port and block flow in both directions.

2. Manufacturer: a. ASAHI-America. b. Hayward. c. NIBCO. d. Georg Fischer.

D. PVC/CPVC Ball Valve, 3-inches through 6-inches: 1. True union type manufactured to ATSM F 1970 and constructed from PVC Type 1,

ASTM D 1784 Cell Classification 12454 or CPVC Type IV, ASTM D 1784 Cell Classification 23447; O-rings shall be EDPM; ball seats of PTFE; handles of polypropylene; supplied with solvent-welded connections or flanged ends drilled to ASME B16.4; approved for potable water service; provide a pressure relief hole drilled on the low pressure side of ball; rated at 150 psi at73oF; and shall be full port and block flow in both directions.

2. Manufacturers: a. ASAHI-America. b. Hayward c. NIBCO. d. Georg Fischer

E. Stainless Steel Ball Valve, ½-inch to 2-inches: 1. Three-piece body, full port, vented ball, block-out proof stem, Type 316 stainless

steel trim, reinforced TFE seat and seal, threaded ends, lever operator, rated 1000-psi CWP. Conforms to MSS SP-110.

2. Manufactures: a. Contromatics. b. Crane Valve Group c. NIBCO.

F. Stainless Steel Ball Valve, 2-inches to 12-inches:

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1. Unibody design, blowout-proof stem, Type 316 stainless steel trim, mounting pad, fire safe, vented ball, flanged ends, rated 275-psi CWP. Conforms to MSS SP-72 and MSS SP-25.

2. Manufactures: a. NIBCO.

2.6 CHECK VALVES

A. PVC/CPVC Check Valve, 4 inches and Smaller: 1. True union type manufactured to ASTM F-1970 and constructed from PVC Type 1,

ASTM D-1784 Cell Classification 12454 or CPVC Type IV, ASTM D-1784 Cell Classification 23447; O-rings and seals shall be EPDM or Viton®; ball seats of PTFE or standard O-ring type; approved for potable water service; having replaceable valve components; and rated 150-psi at 70 degrees F.

2. Manufacturers: a. ASAHI-America. b. Hayward c. NIBCO. d. Georg Fischer.

2.7 APPURTANCES

A. Manual Operators: 1. Provide manual operators on valves, except those which are equipped with power

actuated operators or designed for automatic operation. a. Operator force not to exceed 40 pounds under any operating conditions,

including initial breakaway. Gear reduction operator when force exceeds 40 pounds.

b. Operator self-locking or equipped with self-locking devices. c. Position indicator on quarter-turn valves d. Worm and gear operators one-piece design worm-gears of gear bronze

material. Worm hardened alloy steel with thread ground and polished. Traveling nut type operators threaded steel reach rods with internally bronze or ductile iron nut.

2. Exposed Operator: a. Galvanized and painted handwheels. b. Lever operators allowed on valves 6 inches and smaller. c. Cranks on gear operators. d. Chain wheel operator with tie backs, extension stem, floor stands, and other

accessories to permit operation from normal operation level. e. Valve handles to take a padlock and handwheels a chain and padlock. f. Handwheels to comply with requirements of AWWA C500, Section 3.15

“Wrench Nuts and Handwheels.” 3. Buried Valves: Wrench Nuts:

a. Buried Valves: 2-1/2 Inch and Smaller: Provide cross handle for operation by a forked key.

b. Buried Valves, 3-Inch and Larger: Provide wrench nuts on buried valves, on valves which are to be operated through floor boxes and where shown on Drawings. 1) Comply with requirements of AWWA C500, Section 3.15 “Wrench Nuts

and Handwheels.” 2) Furnish no less than two operating keys for operation of wrench nut

operating valves. c. Provide concrete pad, 2 foot square by 6-inch thick concrete around valve box

at ground surface.

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4. Design buried service valves for quarter-turn valves to withstand 450 foot-pounds of input torque at the fully open or FULLY CLOSED positions, grease packed and gasketed to withstand a submersion in water to 10-psi.

5. Buried valves shall have a valve box. Valve box and bonnet shall be cast iron. All components of shaft extensions shall be Type 316 stainless steel including nut shaft, shaft housing and guides.

6. Extension stem diameter shall be 1-inch or diameter of valve shaft, which ever is greater.

7. Stem guides made of cast iron with bronze bushings with adjustable offset. Provide stem guides at 5-foot intervals.

B. Above Ground Service: 1. 3-inch and Larger: OS&Y, gear operators all valves 16-inch and larger unless

otherwise noted. 2. Chain Wheel Operator: Provide for valves having a centerline six feet or more above

the floor, unless otherwise noted. a. Chain Wheel and Guide: Handwheel direct mounted, with galvanized or

cadmium-plated chain.

C. Operating Stands: 1. Provide fabricated steel or cast iron operating stands in locations shown on the

Drawings. 2. Support handwheel or operator approximately 36 inches above finish floor. 3. Handwheel diameter will not be less than 8 inches. 4. Provide sleeve made for opening in floor beneath each operating stand. 5. Provide suitable thrust bearing in each operating stand to carry weight of extension

stem.

D. Valve Boxes: 1. Cast iron, extension sleeve type, suitable for depth of cover required by Drawings. 2. Not less than 5 inches in diameter and minimum thickness at any point of

3/16 inches; provide valve boxes with suitable cast iron bonnets, bases and covers. 3. Provide covers; cast thereon an appropriate name designating service for which

valve is used. 4. When located in traffic areas, designed for H-20 loadings. 5. Set valves and valve boxes plumb; place each valve box directly over valve it serves,

with top of box flush with finished grade. 6. As shown on Drawings, provide concrete pad around valve surface box at ground

surface.

E. Extension Stem: 1. Provide extension stem when depth of valve is more than 3 feet below finish grade. 2. Provide extension stem with wrench nut locating the wrench nut 6 inches below

ground surface and/or box cover. 3. Extension stem shall locate wrench nut in floor box.

F. Floor Box and Stem: Plain type for support of non-rising type stem, complete with stem, operating nut, and stem guide brackets. Provide stainless steel guides with adjustable offset. Spaced such that stem L/R ratio does not exceed 200. Anchor bots to be Type 316 stainless steel.

G. Torque Tube: Where operator for quarter-turn valve is located on floor stand, furnish extension stem torque tube of a type properly sized for maximum torque capacity of valve.

H. Identification: Provide valve identification tags in accordance with Section 10952 “Identification, Stenciling, and Tagging” and as specified in the various Valve Schedules and as shown on the Drawings.

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PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine piping system for compliance with requirements for installation tolerances and other conditions affecting performance. 1. Proceed with installation only after unsatisfactory conditions have been corrected.

B. Examine valve interior for cleanliness, freedom from foreign matter, and corrosion. Remove special packing materials, such as blocks, used to prevent disc movement during shipping and handling.

C. Operate valves in positions from fully open to fully close. Examine guides and seats made accessible by such operations.

D. Examine threads on valve and mating pipe for form and cleanliness.

E. Examine mating flange faces for conditions that might cause leakage. Check bolting for proper size, length, and material. Verify that gasket is of proper size, that its material composition is suitable for service, and that it is free from defects and damage.

F. Do not attempt to repair defective valves; replace with new valves.

3.2 INSTALLATION

A. General: 1. Install valves, floorstands, valve boxes, and appurtenances in accordance with the

Drawings and manufacturers instructions. 2. Install valves and operators or actuators to provide for ease of access and operation. 3. Install buried valve

B. Flanged Ends: 1. Bolt holes shall straddle vertical centerline of pipe. 2. Clean flange faces, insert gasket and bolts, and tighten nuts progressively and

uniformly.

C. Threaded Ends: 1. Clean threads by wire brushing or swabbing. 2. Apply joint compound.

D. Valve Installation: 1. Piping installation requirements are specified in other Division 15 Sections. Drawings

indicate general arrangement of piping, fittings, and specialties. 2. Install valves with unions or flanges at each piece of equipment arranged to allow

service, maintenance, and equipment removal without system shutdown. 3. Locate valves for easy access and provide separate support where necessary.

Provide access doors in finished walls and plaster ceilings for valve access. 4. Install valves in horizontal piping with stem at or above center of pipe.

a. Butterfly valves will be installed with stem horizontal to allow support for the disc and the cleaning action of the disc.

b. Unless otherwise noted, install operating stem vertical in horizontal runs of pipe having centerline elevations 4 feet 6 inches or less above finished floor.

c. Unless otherwise noted, install operating stem horizontal in horizontal runs of pipe having centerline elevation between 4 feet 6 inches and 7 feet above finish floor.

5. Install valves in position to allow full stem movement. 6. Install check valves for proper direction of flow and as follows:

a. Swing Check Valves: In horizontal position with hinge pin level. b. Dual-Plate Check Valves: In horizontal or vertical position, between flanges. c. Lift Check Valves: With stem upright and plumb.

7. Butterfly valves shall be installed with stems horizontal.

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8. If a plug valve seat position is not shown, locate as follows: a. Horizontal low: The flow shall produce an “unseating” pressure; the plug shall

open into the top half of valve. b. Vertical Flow: Install seat in the highest portion of the valve.

9. Install line size ball valve and union upstream of each solenoid valve, in-line flow switch, or other in-line electrical device, excluding magnetic flowmeters for isolation during maintenance.

10. Provide union or flanged connection within two feet of each threaded end valve unless valve can be otherwise easily removed from piping.

11. Install safety isolation valves on compressed air lines which have stored energy in accordance with latest OSHA requirements.

E. Valve Operators: 1. Manual Operators:

a. Provide manual operators on valves, except those which are equipped with power actuated operators or designed for automatic operation.

b. Unless otherwise specified in the various valve sections, provide handwheel or lever operators for valves, 6-inch and smaller, and gear operators for valves, 8-inch and larger.

2. Buried Service: a. 2-1/2 inch and smaller: b. 3-inch and Larger (not installed in Valve Vault):

1) Provide stainless steel shaft extension and wrench nut. Minimum extension stem diameter shall be 1-inch or diameter of valve shaft, whichever is larger.

2) Provide valve box, bonnet and cover. c. Wrench nut, handwheel and gear operator shall comply with the requirements

of applicable AWWA Standards. d. As shown on the Drawings, buried Valves, 8-inch and larger, shall rest on

concrete pad. Pad shall extend full width of trench, from back-to-back of hub or flange.

3. Above Ground Service: a. 3-inch and Larger: gear operators all valves 8-inch and larger, unless otherwise

noted. b. Chain Wheel Operators: Install chain wheel operators on valves 4-inch and

larger and more than 84 inches above floor, unless otherwise noted. Extend chains to 60 inches above finished floor elevation. Where chains hang in normally travel areas, use appropriate “L” type tie-back anchors.

4. Electric and pneumatic operators and actuators shall comply with the requirements of the applicable Division 15 operator section.

3.3 FIELD COATING 1. Contractor shall apply finish coat with product described in Specification

Section 09910. 2. For valves with bonnets and submerged in basins, the section of the bonnet

assembly below the top wall of the basin shall be coated with product described in Specification Section 09910. Section of bonnet assembly above the basin top of wall shall be coated with product described in Specification Section 09910.

3. Valve coating shall be applied in accordance with Specification Sections 09910.


A. Perform Tests and Inspections: 1. Valve may be either tested while testing pipelines, or as a separate step. 2. Test that valve opens and closes smoothly with operating pressure on one side and

atmospheric pressure on the other, in both directions for two-way valve and applications.

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3. Count and record the number of turns to open and close valve; account for any discrepancies with manufacturer’s data.

4. Set, verify, and record set pressures for all relief and regulating valves. 5. Automatic valves to be tested in conjunction with control system testing and as

specified under Manufacturer’s services.

B. Prepare test and inspection reports.

3.5 MANUFACTURERS’ SERVICES

A. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and valve installations, including connections, and to assist in testing. Provide in accordance with Section 01640 “Manufacturers’ Services.”

B. For every three (3) powered operated valves or gates, or less, provided on the Project, a qualified manufacturers’ representative shall be present at the Project site for the minimum person-days, travel excluded, as indicated:

Person-Days Activity Description

1/2 Inspection of valve installation, functional testing, and certification valve assembly has been installed and tested in accordance with manufacturer’s instructions and these specifications.

1/2 Plant startup. 1/2 Training of OWNER’S personnel in operation and maintenance.

C. Startup Services; Comply with the requirements of Section 01810 “Equipment Testing and Facility Startup.”

D. Training of OWNER”S Personnel: Comply with the requirements of Section 01820 “Demonstration and Training.”

3.6 VALVE SCHEDULE

A. Refer to the Drawings for the Valve Schedule. The Valve Schedule is not guaranteed to be accurate, and lists valves 6-inch and larger and valves of all sizes with electric/pneumatic actuators. Refer to Drawings for type, end connections, and locations for all valves.

END OF SECTION

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VALVES, GATE F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15101 VALVES, GATE.DOC

SECTION 15101 VALVES, GATE

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes the following gate valves: 1. AWWA Ductile-Iron Resilient-seated gate valves, 3-inch and larger.

B. Related Sections: 1. Refer to Section 15100 “Valves, Basic requirements and Miscellaneous;”

a. For information regarding submittals; quality assurance; coordination; material delivery, handling, and storage; projection conditions; design requirements; coating requirements; other materials; installation of piping systems; field testing; and related work.

b. For gate valves 2-1/2 inch and smaller.

PART 2 - PRODUCTS

2.1 GENERAL

A. Valve to include operator, actuator, handwheel, chain wheel, extension stem, floor stand, worm and gear operator, operating nut, chain, wrench, valve boxes, and all accessories and related equipment for a complete operating system. Refer to Drawings for valves requiring limit switches, electric or pneumatic operators, and related controls.

B. Comply with the following: 1. Suitable for intended service. Renewable parts not to be of a lower quality than

specified. 2. Same size as adjacent piping. 3. Ends to suit adjacent piping. 4. Operator sized to operate valve for full range of pressures and velocities. 5. Open by turning counterclockwise, unless otherwise specified. 6. Factory mount operator, actuator and accessories.

C. Obtain all valves and associated manual operators from a single manufacturer.

D. Gate valves shall be of the resilient seated design.

2.2 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. ACIPCO American Flow Control 2. American R/D 3. Clow Valve Co. 4. Kennedy 5. Mueller 6. M&H 7. U.S. Pipe Metroseal

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2.3 VALVE DESCRIPTION

A. AWWA Gate Valves, 3-inch and Larger, Resilient-Seated: 1. Construction: Ductile-iron body with full round port opening and integrally cast guides;

smooth valve bottom with no recessed areas; bonnet cover. 2. Position: Vertical 3. Gate shall be completely covered with rubber on all interior and exterior ferrous

surfaces. The rubber shall be secured to the gate body, including the part which houses the stem nut.

4. Stem: Cast, forged, or rolled bonze 5. Stem Seals: Double O-ring, Buna-N protected by grit and dust cap 6. Stem Nut: Brass or bronze 7. Seats: Resilient seats bonded to wedge for seating against a corrosion resistance

surface. 8. Nylon bushing and Teflon washer for friction protection 9. Operating Pressure:

a. 12-inch and smaller, 200 psig b. 16-inch and 20-inch, 150 psig

10. Flange Ends (Unless other wise specified): a. Above Ground: Flanged, ANSI B16.1, Class 125. b. Buried Service: Mechanical joints, ANSI/AWWA C111/A21.11.

11. Coating: In accordance with Section 09910 Comply with requirements of AWWA C515 “Resilient-Seated Gate Valves for Water Supply Service.”

2.4 OPERATORS

A. Buried Service: 1. 3-inch and Larger:

a. Non-rising stem with stainless steel shaft extension and wrench nut. Minimum extension stem diameter shall be 1-inch or diameter of valve shaft, whichever is larger. All components shall have continuous welded joints. Provide stem guides or rock shields at 5-foot intervals.

b. Valve Box: Three piece screw type 5 ½-inch diameter, cast iron construction. 1) Manufacturer

a) Clow, Model F-2454 or approved equal

B. Above Ground Service: 1. 3-inch and Larger: OS&Y, gear operators all valves 16-inch and larger unless

otherwise noted. 2. Chain Wheel Operator: Provide for valves having a centerline six feet or more above

the floor, unless otherwise noted.

C. Wrench nut, handwheel and gear operator shall comply with the requirements of applicable AWWA Standard previously reference.

D. Electric operators shall comply with the requirements of the applicable Section 15139 “Electric Operators.”

2.5 ACCESSORIES

A. Identification: Provide valve identification tags in accordance with Section 10952 “Identification, Stenciling, and Tagging.”

B. Refer to Section 15100 “Valves, Basic Requirements and Miscellaneous” for addition accessories requirements.

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PART 3 - EXECUTION

3.1 INSTALLATION

A. Refer to Section 15100 “Miscellaneous Valve” for Execution requirements for the installation, field quality control, and manufacturer’s services.

3.2 VALVE SCHEDULE

A. The Gate Valve Schedule after “END OF SECTION” is part of this Section. The Valve Schedule is not guaranteed to be accurate, and lists valves 6-inch and larger and valves of all sizes with electric/pneumatic actuators only. Refer to Drawings for type, end connections, and locations for all valves.

END OF SECTION

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GATE VALVE SCHEDULE

Tag No. Location Size (inches) Type/End Connection

Process Fluid Service New/Existing Remarks

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VALVES, BUTTERFLY F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15102 VALVES, BUTTERFLY.DOCX

SECTION 15102 VALVES, BUTTERFLY

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes: 1. The CONTRACTOR shall furnish and install rubber-seated butterfly valves, operators

and appurtenances complete as shown on the Plans and specified herein.

1.2 REFERENCES

A. Referenced Standards: Rubber seated shall be tight closing type conforming to the latest version of AWWA C504 standards. 1. AWWA C-540 - "Power-Activating Devices for Valves and Sluice Gates." 2. AWWA C-550 - "Standard Specification for Protective Interior Coatings for Valves and

Hydrants." 3. ASTM A-48 - "Standard Specification for Grey Iron Castings." 4. ASTM A-126 - "Standard Specification for Grey Iron Castings for Valves, Flanges, and

Pipe Fittings." 5. ASTM A-536 - "Standard Specification for Ductile Iron Castings." 6. ANSI - "American National Standards Institute." 7. ANSI/NSF - "Standard 60/61."

1.3 SYSTEM DESCRIPTION (NOT USED)

1.4 SUBMITTALS

A. Product Data: 1. Comply with the general requirements of Division 1 and the supplemental

requirements below. 2. Submit one drawing or illustration showing unit construction for each type and size

valve used. 3. Submit the following information for each valve:

a. Specific application in plant expressed in terms of service and contract drawing number where shown.

b. Description including type of valve; type, size, and model number of operator with number of turns to open; and accessories included.

c. Size and end connections. d. Maximum non-shock working pressure for which valve is designed. e. Materials of construction and coatings for valves, operators and accessories. f. K or Cv value. g. Manufacturers' make and model. h. Seat orientation. i. Size, length, and material of extension stems with number of supports required. j. Direction to open.

4. Submit the following information for geared operators: a. Type of gearing. b. Type of lubrication. c. Size of handwheel, lever or crank. d. Input torque required to develop required output torque. e. Orientation and dimensions of operator. f. Manufacturers' make and model.

5. If catalog bulletins are used to communicate above information, mark out inapplicable information.

6. Operation and Maintenance Data: a. Comply with the requirements of Division 1.

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B. Quality Assurance/Control Submittals 1. Affidavits:

a. Submit affidavits of compliance with the reference standards.


A. Each valve shall have manufacturer's nameplate in stainless steel showing the pressure ratings, serial and model numbers, year manufactured and other pertinent data.

B. Valve supplier shall maintain a complete stock of spare parts in the State of Texas or shall indicate that parts will be delivered upon 48 hours of receipt of request.

C. Butterfly valves and manual operators shall be completely assembled at the factory, adjusted for correct seating, and tested in accordance with the AWWA C-504 standard. Factory adjustments and operational tests shall be performed on each valve with the valve oriented in the same position as the installed field position. The valves shall be cycled five times (full open to full close) and successfully seat tested each cycle to certify proper seating. Seat adjustments and manual indicators shall be set and checked at the factory.

D. For valves 24 inches and larger, the manufacturer shall conduct ultra-sound testing on each of the valve bodies and discs in addition to hydrostatic testing of each valve body. The manufacturer shall perform the hydrostatic valve tests in accordance with AWWA C-504 and provide certified reports of test results. The manufacturer shall notify the OWNER three weeks prior to testing so that the OWNER may witness tests. Hydrostatic test pressures shall be 150 psi for the bodies and 150 psi for the discs and seats.

E. All surfaces and materials in contact with water, or in contact with a chemical being added to water that is being treated for potable use, shall conform to ANSI/NSF 61 and be certified by an organization accredited by ANSI, or shall meet the TCEQ requirements for contact with potable water.


A. Comply with the requirements of the General Conditions and manufacturers recommendations.

1.7 PROJECT CONDITIONS (NOT USED)

1.8 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components that fail(s) in materials or workmanship within specified warranty period. 1. Warranty Period: Two (2) years from date of Substantial Completion of this

equipment. 2. Cost for the removal, shipment, repair and installation by CONTRACTOR shall be

included in warranty, as well as correction of defective work.


A. Manufacturers of butterfly valves shall demonstrate a minimum of 10 years of experience in similar applications for sizes of valves being furnished. References shall be furnished upon request.

1.10 MAINTENANCE (NOT USED)

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PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Crispin, K-Flo

B. DeZurik

C. Pratt

2.2 GENERAL

A. Obtain all butterfly valves and associated manual operators of a given type from a single manufacturer.

B. Valve operators to turn to left, counterclockwise, to open and to right, clockwise, to close. All valves shall have position indicators.

C. End connections to be compatible with those specified for pipe. Mechanical joints shall conform to ANSI/AWWA C11/A21.11. Flanges shall conform to ANSI B16.1 and have a pressure rating to meet the requirements of the adjoining pipe.

D. Furnish geared operators for all valves in pressure piping systems (≥10 psig working pressure) and valves 8 inches and larger, unless otherwise specified.

E. Furnish geared operators with the following features unless otherwise specified. 1. Weatherproof enclosure. 2. Grease lubricated design. 3. Closes valve when turned clockwise. 4. Position indicator.

F. All internal materials for valves shall withstand corrosion.

G. All valves in submerged service shall utilize 316 stainless steel hardware and bolts.

H. Valve serial number, number of turns to open, manufactures, type, size, and operator/actuator model and size shall be shown on valve tag for each valve furnished. Buried valves shall have tag mounted on concrete at valve box cover. All tags shall have reproduction in O&M Manual.

I. The water being delivered through the valves may be treated with chlorine, chlorine dioxide, and/or chloramines. The materials used to manufacture the valves shall be resistant to chlorine, chlorine dioxide, and chloramine oxidation.

J. Buried valves shall be quarter-turn butterfly valves that utilize 316 stainless steel shaft extensions with stem guides or rock shields, 2-inch square nut, and adjustable valve boxes with covers. A 2-inch nut shall be located within 18 inches of grade.

K. Fasteners on buried valves, valves in manholes and vaults, MJ joints, flanges, and restraints shall be 316 stainless steel. Buried MJ fitting bolts may be Corten. Fasteners on exposed valves shall be 316 stainless steel.

L. Areas on the disc and body that are subject to cavitation damage shall be constructed of materials that are resistant to the effects of cavitation.

M. Maximum velocity through the valves should be assumed to be 12 feet per second when fully opened.

2.3 BUTTERFLY VALVES DETAILS

A. Provide valves as shown on the Plans.

B. Valve type: AWWA C504 rubber-seated butterfly valve.

C. Non-shock working pressure: 150 psi, minimum, sized to meet test pressure of pipeline: 1. Body type: Short body flanged, unless shown otherwise on the plans.

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2. Valve flanges for valves 24-inch and larger and for all exposed valves shall have ANSI Class 125 or Class 250 flanges based on the corresponding pipe class. Buried valves smaller than 24-inch shall utilize MJ joints. Two (2) trunnions for shaft bearings shall be integral with each valve body. Valve bodies shall be hydrostatic tested to a minimum of working pressure class.

D. Valve construction: 1. Body: Cast iron (ASTM A126 Class B) or ductile iron (ASTM A-536 Grade 65/45/12)

for valves smaller than 24-inch diameter. Ductile iron (ASTM A-536 Grade 65/45/12) for valves 24 inches and larger.

2. Shaft: Solid stainless steel, type 316. 3. Disc: Ductile iron ASTM A-536, Grade 65/45/12. Operating pressure of valve disc

shall be 150 psi. Valve discs shall be hydrostatic tested to a minimum of 150 psi. 4. Seats: EPDM rubber mechanically secured to the body. Valve seats shall provide

tight shut-off at 0 to 150 psi operating pressure. The seat shall be field adjustable and field replaceable. The mating surface shall be 18-8 stainless steel or a 95 percent pure nickel overlay.

5. Bearings: Fitted sleeve type. Bearings shall be corrosion resistant and self-lubricated materials that will not deteriorate neutral or synthetic rubber.

6. Shaft Seals: Split-V or O-ring type, suitable for buried service requiring no gland adjustment.

2.4 ACCESSORIES (NOT USED)

2.5 FINISHES

A. Paint exterior of valves and operators as shown on the plans and specified in Division 9, Painting, colors to be selected by OWNER. Interior of valves shall be factory lined with NSF approved epoxy meeting the requirements of Division 9 and AWWA C550. Flange faces shall be protected from atmospheric corrosion.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install all valves, floorstands, and appurtenances in complete accordance with the plans, approved shop drawings and manufacturer’s instructions and recommendations.

B. Install valves and valve operators to provide for ease of access and operation. Install seat adjustment side of valve opposite of headers or common piping.

C. Install butterfly valves with shafts horizontal unless otherwise shown.

D. Space stem guides at 8 feet center to center maximum or closer if recommended by manufacturer.

3.2 ACTUATOR MOUNTING

A. The valve supplier shall be responsible for the actuator mounting. Refer to Division 15 Section 15139 “Electric Operators” for requirements.


A. Retain a qualified representative of the manufacturer to perform the following services: 1. Inspect the completed installation and note deficiencies. 2. Assist the CONTRACTOR during start-up, adjusting, and site testing of competed

installation as required. 3. Instruct OWNER personnel in the operations and maintenance of the equipment. 4. Stem extensions (and boxes on buried valve) shall be installed plumb within ±1-inch in

10 feet.

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B. Field Testing: Plant testing and startup will be in accordance with Division 1. Piping systems will be tested in accordance with Division 15. All valves shall be operated over the full range of travel without excessive force for at least two complete cycles; open-closed-open-closed. Valve shall not hang and shall seat and unseat to/from fully closed position. Testing shall be done after actuators and stem extensions are installed. Verify valve tag is installed and correct. Verify valve position indicator correctly reflects valve positions and limit switches (if used) are set correctly. Valves with motor or pneumatic actuators shall be operated with handwheel as well as automatic actuator.

3.4 SCHEDULE

A. The Butterfly Valve Schedule after “END OF SECTION” is part of this Section. The Valve Schedule is not guaranteed to be accurate, and list valves 6-inch and larger, unless it is a control valve. Refer to Drawings for type, end connections, and locations for all valves.

END OF SECTION

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BUTTERFLY VALVE SCHEDULE

Tag No. Location Size (inches)

Type/End Connection


V-672 Plant Water Pump Station

6 Flanged PW Open/Close New





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VALVES, PLUG F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15103 VALVES, PLUG.DOC

SECTION 15103 VALVES, PLUG

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes the following valves: 1. Eccentric plug valves, 3-inch and smaller. 2. Eccentric plug valves, 4-inch and larger.

B. Related Sections: 1. Refer to Section 15100 “Miscellaneous Valves;”

a. For information regarding submittals; quality assurance; coordination; material delivery, handling, and storage; projection conditions; general requirements; material requirements; installation of valves; field testing; and related work.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, those listed for the various valves.

2.2 VALVE DESCRIPTION

A. Eccentric Plug Valve, 3-inches and Smaller: 1. Description: Non-lubricated type, drip-tight shut off with pressure in either direction,

cast body, flanged (ANSI B16.1 Class 125 and ANSI B16.5 Class 150) or threaded ends (NPT requirements of ANSI B1.20.1) for rigid joints and mechanical joints for buried valves. Design similar to MSS SP-108.

2. Body: a. Cast iron, ASTM A126, Class B, or carbon steel, ASTM A216, Grade WCB,

with bolted bonnet of same material. b. Body receives a coating of corrosion-resistant nickel seat. c. Provide a grit seal for upper and lower journal.

3. Plug: a. Plug with upper and lower shaft in a one-piece casting, with round or

rectangular port. b. Material: NBR face, same material as body for cast iron body, for carbon steel

body pug to be Type 316 stainless steel. 4. Stem Seal: NBR or PTFE. 5. Body and Bonnet Bearing: Type 316L stainless steel. 6. Bonnet Screws and Nuts: Stainless steel. 7. Port Area: 100% of connecting pipe area. 8. Pressure Ratings:

a. Cast iron: 175-psi CWP b. Carbon Steel: 285-psi CWP

9. Manufacture and Product: a. DeZurik b. Pratt

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c. Val-Matic

B. Eccentric Plug Valve, 4-inches and Larger: 1. Description: Non-lubricated type, drip-tight shut off with pressure in either direction,

cast body, flanged (ANSI B16.1 Class 125 and ANSI B16.5 Class 150) for rigid joints and mechanical joints for buried valves. Design similar to MSS SP-108.

2. Body: a. Cast iron, ASTM A126, Class B, or ductile iron, ASTM A536, Grade 65-45-12,

with bolted bonnet of same material. b. Body receives a welded overlay of corrosion-resistant nickel seat machined to

a smooth finish 3. Plug:

a. Plug with upper and lower shaft in a one-piece casting, with round or rectangular port.

b. Material: Same as body with resilient facing of NBR. 4. Body and Bonnet Bearing: Type 316L or Type 316 stainless steel. 5. Packing: NBR or PTFE V-Type. 6. Bonnet Screws and Nuts: Stainless steel. 7. Port Area: 100% of connecting pipe area valves 4-inches and smaller, 85% on 16-inch

and smaller, 80% on 18-inch through 24-inch, 75% on 30-inch and larger. 8. Pressure Ratings:

a. 4-inch to 12-inch: 175-psi CWP b. 14-inch and Larger: 150-psi CWP

9. Manufacture and Product: a. DeZurik b. Pratt c. Val-Matic d. GAIndustries

2.3 OPERATORS

A. Buried Service: 1. 3-inch and Larger (not installed in Valve Vault):

a. Provide stainless steel shaft extension and wrench nut. Minimum extension stem diameter shall be 1-inch or diameter of valve shaft, whichever is larger.

b. Provide valve box, bonnet and cover.

B. Above Ground Service: 1. 4-inch and Smaller: Lever 2. 6-inches and Larger: Totally enclosed, geared, manual operator with hand wheel,

wrench nut, or chain wheel as required. 3. Chain Wheel Operator: Provide for valves having a centerline six feet or more above

the floor, unless otherwise noted.

C. Wrench nut, handwheel and gear operator shall comply with the requirements of Section 15100 “Miscellaneous Valves.”

D. Electric and pneumatic operators and actuators shall comply with the requirements of the applicable Section 15113 “Electric Valve and Gate Operators”

2.4 ACCESSORIES



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PART 3 - EXECUTION

3.1 INSTALLATION

A. Refer to Section 15100 “Valves, Basic Requirements and Miscellaneous” for Execution requirements for the installation, field quality control, and manufacturer’s services.

3.2 VALVE SCHEDULE

A. The Plug Valve Schedule after “END OF SECTION” is part of this Section. The Valve Schedule is not guaranteed to be accurate, and lists valves 6-inch and larger and valves of all sizes with electric/pneumatic actuators. Refer to Drawings for type, end connections, and locations for all valves.

END OF SECTION

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PLUG VALVE SCHEDULE



V-802 Dewatering Building

8 Flanged SLG Open/Close New













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F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15104 VALVES, CHECK.DOC

SECTION 15104 VALVES, CHECK

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes the following valves: 1. MSS-SP-71 Swing check valves, 2-inches through 12-inches. 2. AWWA Swing check valves, 2-inches through 36-inches. 3. Ball check, iron body, 3-inch and larger. 4. Double-disc check valves, 2-inches through 36-inches. 5. Rubber flapper check valves, 2-inches through 36-inches. 6. “Duckbill” elastomeric check valves, 2-inches through 84-inches. 7. Silent check valves, 1-inch and Larger.

B. Related Sections: 1. Refer to Section 15100 “Miscellaneous Valves”:

a. For information regarding submittals; quality assurance; coordination; material delivery, handling, and storage; projection conditions; design requirements; other materials; installation of piping systems; field testing; and related work.

b. For PVC check valves, 4-inches and smaller, and bronze check valves, 3-inches and smaller.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, those listed for the various valves.

2.2 CLASS 125 SWING CHECK VALVE

A. Class 125 Iron Body Check Valve, 2-inch through 12-inch: 1. Cast Iron body, bolted bonnet, horizontal swing, renewable seat and disc, threaded or

flange ends, outside lever and spring, rated 125-psi SWP and 200-psi CWP. Conforms to MSS SP-71 Type 1.

2. Manufacturer: a. Crane b. NIBCO c. Powell, Wm. Co.

2.3 AWWA SWING CHECK VALVES

A. AWWA Swing Check Valve, 2-inches through 30-inches: 1. AWWA C508, flanged end, cast iron body, bronze mounted, full opening swing type,

solid bronze hinges, Type 316 stainless steel hinge shaft, fitted with adjustable outside lever and weight.

2. Disc constructed of bronze with a rubber seal recessed or cast iron, rubber faced. Valve construction shall permit removal of internal components without removal from the pipeline.

3. Valve, 2-inches through 12-inches rated 175-psi CWP and 14-inches and larger, 150 psi CWP.

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4. Manufacturers: a. ACIPCO, American Flow Control b. GA Industries c. M&H Valve Co.

2.4 BALL CHECK VALVE

A. Ball Check Valve, 3-inches and Larger: 1. Flanged end, iron body, with cleanout and hollow steel ball, vulcanized nitrile rubber

exterior, suitable for vertical up or horizontal flow, rated 150-psi CWP. 2. Manufacturers:

a. FLYGT Corp. b. GA Industries

2.5 DOUBLE DISC CHECK VALVE

A. Double Disc Check Valve, 2-Inches through 54-Inches: 1. Wafer style, spring loaded, two piece Type 316 stainless steel disc, Type 316

stainless steel shaft, Type 316 stainless steel torsion spring and have an integrally molded elastomer seat vulcanized to the body.

2. Valve body shall be cast iron for 125-psi rating and cast steel for 150-psi rating, of the lugged wafer style.

3. Valve shall be designed to fit between ANSI flanges and valves, 5-inches and larger, shall be fitted with a lifting eye bolt for installation purposes.

4. Valve, 2-inches through 12-inches, rated 250-psi CWP, and 14-inches through 54-inches, rated 150-psi CWP.

5. Manufacturer and Product: a. APCO; Series 9000 b. Crane Valve Group; Duo-Chek II c. Pratt; Series 740

2.6 RUBBER FLAPPER CHECK VALVE

A. Rubber flapper Check Valve, 2-inch through 36-inches: 1. Iron body and cover, steel-reinforced Buna-N disc, seat constructed at 45 degree

angle, flanged ends, rated for 150-psi CWP. 2. Manufacturer and Product:

a. APCO Willamette; Series 100. b. Val-Matic; Swing-Flex c. Pratt; RD-Series

2.7 SPRING ASSISTED RUBBER FLAPPER SWING CHECK VALVE

A. Class 125, ANSI/ASME B16.1

B. Acceptable Manufacturers 1. Val-Matic Surgebuster 2. Crispin RF-ASR 3. Golden Anderson Slaminator

C. Materials 1. Body and cover: ductile iron 2. Flapper: Buna-N, steel reinforced 3. Disc accelerator: stainless steel

2.8 ACCESSORIES


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PART 3 - EXECUTION

3.1 INSTALLATION

A. Refer to Section 15100 “Miscellaneous Valves” for Execution requirements for the installation, field quality control, and manufacturer’s services.

3.2 VALVE SCHEDULE

A. The Check Valve Schedule after “END OF SECTION” is part of this Section. The Valve Schedule is not guaranteed to be accurate, and lists valves 6-inch and larger and valves of all sizes with electric/pneumatic actuators. Refer to Drawings for type, end connections, and locations for all valves.

END OF SECTION

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CHECK VALVE SCHEDULE


Process Fluid New/Existing Remarks


6 Swing/Flanged PW New


6 Swing/Flanged PW New


6 Swing/Flanged SLG New


6 Swing/Flanged SLG New

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ELECTRIC MOTOR OPERATORS F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15113 ELECTRIC MOTOR OPERATORS.DOCX

SECTION 15113 ELECTRIC MOTOR OPERATORS

PART 1 - GENERAL

1.1 SCOPE

A. Furnish all labor, materials, equipment and incidentals required, provide installation assistance and test, complete and ready for operation, the electric valve and gate operators with controls as specified.

B. The operators shall be provided by the respective valve or gate manufacturer, but shall conform to this Section. The intent of this requirement is to give the valve or gate supplier the authority and responsibility to provide a coordinated valve and operator.

C. All electric operators powered with 208-volts AC/three-phase/60 Hz and provided under this Section shall be the products of a single manufacturer, regardless of the sources of the valves which they control. Further, to the extent possible, all operators provided hereunder shall be of the same model series and type. Coordinate between suppliers as required.

1.2 SUBMITTALS

A. With each valve or gate to which an operator is attached, submit with the valve or gate submittal, in accordance with Section 01301 “Submittals”, the name of the operator manufacturer, catalog sheets showing operator characteristics and dimensions, and the following items: 1. Dimensional drawings of each item of equipment and auxiliary apparatus to be

furnished. 2. Mechanical and electrical connection details. 3. Electrical schematic wiring diagram and other data as required for complete operator

installation. 4. Literature and drawings describing the equipment in detail, including parts list and

materials of construction, operating speeds, range of adjustment for adjustable items and other items necessary to indicate full conformance with the detailed Specifications.

5. Operation and maintenance data. 6. Installation instructions.

B. Design Data 1. Submit manufacturer's data showing operator characteristics of torque, speed, power

requirements and consumption, options provided, operational flexibility characteristics to be provided, and total unit weight. This information shall be prepared specifically for each operator size and type proposed. Catalog sheets showing general information and options available will not be acceptable unless inapplicable portions are marked out and applicable items are designated.


A. AWWA C540 - Power-Actuating Devices for Valves and Sluice Gates.


A. Qualifications 1. The equipment covered by these Specifications is intended to be standard valve and

gate operating equipment of proven ability as manufactured by reputable concerns having extensive experience in the production of such equipment. Units specified herein shall be furnished by a single manufacturer. The equipment furnished shall be designed, constructed and installed in accordance with the best practice and methods.

2. The valve or gate manufacturer shall be responsible for the furnishing and performance of the complete valve units, including the operators. The associated valve manufacturer shall be fully responsible for the design, arrangement, and

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operation of all connected components, to ensure that neither harmful nor damaging nor unexpected actions result under any condition within the specified operating ranges.

3. Should equipment which differs from these Specifications be offered and determined to be the equal of that specified, such equipment shall be acceptable only on the basis that any revision in the design and construction of the structure, piping, appurtenant equipment, electrical work, etc., required to accommodate such a substitution shall be made at no additional cost to the OWNER and be as approved by the ENGINEER.

B. Services of Manufacturer's Representative 1. A factory representative, who has complete knowledge of proper operation and

maintenance of the operators, shall be provided to instruct representatives of the OWNER and the ENGINEER on proper operation and maintenance. Training shall include both field and classroom instruction, including the use of such model or prototype equipment as is necessary to provide adequate "hands-on" training. Provided at least 4 hours of training.

2. Factory representative shall inspect installation of the valve operators and conduct a test run of the equipment as specified in Part 3.

3. Services shall be provided as required to place equipment in satisfactory operation, but at least two 8-hour days shall be provided (exclusive of travel time).


A. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the unit and equipment are ready for operation.

B. All equipment and parts must be properly protected against any damage during on-site storage. All compartment heaters shall be powered at all times, whether the operator is in storage or installed but not yet in operation.

C. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the ENGINEER.

D. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.

1.6 MAINTENANCE

A. Furnish one set of all special tools required for the proper servicing of all equipment supplied under these Specifications, clearly identified and packed in suitable sealed container. Furnish the manufacturer's standard set of spare parts for each operator size and type provided.

B. The equipment manufacturer shall submit evidence that he can deliver a replacement for any part furnished within three working days.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include the following: 1. Rotork: IQ Range Multi-Turn with IW Gearbox. 2. Limitorque: MX Series Multi-Turn with PT Series Gearbox 3. Equivalent Model by AUMA with AC01.2 Controller

2.2 GENERAL

A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.

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B. Like items of materials/equipment shall be the end products of one manufacturer in order to provide standardization for appearance, operation, maintenance, spare parts, and manufacturer's service.

C. Equipment weighing over 100 pounds shall be provided with lifting lugs.

D. Stainless steel nameplates with the name of the manufacturer, model number, the rated capacity, speed, and all other pertinent data shall be furnished and attached to the operators.

2.3 ELECTRIC VALVE AND GATE OPERATORS

A. The actuators shall be suitable for use on a nominal 208 volt, 3 phase, 60 Hertz power supply and are to incorporate motor, integral reversing starter, local control facilities, and terminals for remote control and indication connections. Electrical actuators shall be a non-intrusive design.

B. Electric motor-driven valve and gate operators shall include the motor operator, unit gearing, fully machined drive sleeve, declutch lever, stainless steel stem cover (if applicable), local control station, control power transformer, reversing starter, incoming non-fused disconnect with one "a" and "b" auxiliary contact, and auxiliary handwheel. The operators shall be fully self-contained. Control circuitry shall be protected by suitable fuses. Six contact relays shall be provided. The contact relays shall have a minimum rating of 5A, 250VAC. One contact relay shall be dedicated for collective fault (phase failure, motor protection tripped, torque fault) or one of eight other fault groups. The other five indication contact relays shall be selectable from a list of at least 45 parameters including, but not limited to: end position CLOSED, end position OPEN, selector switch in REMOTE mode, torque fault in CLOSED direction, and torque fault in OPEN direction.

C. All valve and gate operators shall conform in all respects to AWWA C540, except as herein modified.

D. All electric valve and gate operators provided hereunder shall conform to the following: 1. NEMA 4X or IP66 watertight enclosure construction. 2. 208 volt motor. Motor and heater compartment required. 3. Position indicators are required. 4. Stem protectors with position indication are required for all gate installations. 5. Electrical controls to be integral with the operator. 6. Electrical actuators shall have open/close service.

E. Actuator Sizing: The actuator shall be sized to guarantee valve closure at the maximum differential pressure. The safety margin of motor power available for seating and unseating the valve shall be sufficient to ensure torque switch trip at maximum valve torque with the supply voltage 10% below nominal. The operating speed shall be such as to give valve closing and opening at approximately 10-12 inches per minute unless otherwise stated in the specification.

F. Ambient Temperature: The actuator shall be capable of functioning in an ambient temperature ranging from minus 13oF (-25oC) to 158oF (70oC).

G. Motor: 1. Motors shall be specifically designed for valve operator service and shall be high

torque, totally enclosed, non-ventilated construction, with motor leads brought into the limit switch compartment without having external piping or conduit box.

2. The electric motor shall be Class F insulated with a time rating of 15 minutes at 104oF (40oC) or twice the valve stroking time, whichever is longer, at an average load of at least 33% of the maximum valve torque.

3. Motors shall be prelubricated. 4. Bearings shall be of the antifriction type. 5. Electrical and mechanical disconnection of the motor should be possible without

draining the lubricant from the actuator gearcase.

H. Motor Protection

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1. The motor shall be de-energized in the event of stall when attempting to unseat a jammed valve.

2. A thermostat imbedded in the windings to protect against overheating shall sense motor temperature.

3. Torque protection reset shall not allow repeated starting in the same direction when control signal is maintained.

4. The actuator shall include a device to ensure that the motor runs with the correct rotation for the required direction of valve travel with either phase sequence of the three phase power supply connected to the actuator.

I. Gearing 1. The design should be such as to allow the gearcase to be opened for inspection or

disassembled without releasing the stem thrust or taking the valve out of service. 2. All main drive gearing must be of metal construction. 3. The unit gearing shall consist of generated helical or spur gears of heat treated steel

and worm gearing. The worm shall be carburized and hardened alloy steel with the threads ground after heat treating. The worm gear shall be alloy bronze accurately cut with a hobbing machine. Ball and roller bearings shall be used throughout.

4. The actuator gearing shall be totally enclosed in oil filled gearcase to allow the operator to be mounted and operational at any angle.

5. Standard gear oil or grease shall be used to lubricate the gearcase. Special or exotic lubricants shall not be used.

J. Hand Operation 1. A handwheel shall be provided for emergency operation engaged when the motor is

declutched by a lever or similar means. 2. The handwheel shall have minimum 8-inch diameter solid wheel with no external

spokes. 3. The handcrank/wheel shall not rotate during electric operation, but shall be

responsive to manual operation at all times except when being electrically operated. 4. The motor shall not rotate during hand operation, nor shall a seized motor prevent

manual operation. 5. When in manual operating position, the unit shall remain in this position until the

motor is next energized at which time the operator shall automatically return to electric operation and shall remain in motor position until handwheel operation is next desired.

6. Alternating from motor to handwheel operation shall be accomplished by a positive declutching lever which shall disengage the motor and motor gearing mechanically, not electrically. The Hand/Auto selection lever should be padlockable in both Hand and Auto positions.

7. It should be possible to select hand operation while the actuator is running or start the actuator motor while the Hand/Auto selection lever is locked in Hand without damage to the drive train. Hand wheel rim pull shall not exceed 80 foot-pounds.

8. The handwheel drive shall be mechanically independent of the motor drive, and any gearing should be such as to allow emergency manual operation in a reasonable time.

9. It shall be possible to disengage the electrical drive with the declutch lever. This disengagement shall not cause any damage to the valve or operator, even while the motor is running.

K. Drive Bushing 1. They shall be furnished with a drive bushing that is detachable for machining, to suit

the valve stem or gearbox input shaft. Normally the drive bush shall be positioned in a detachable base of the actuator. Thrust bearings shall be of the sealed-for-life type when housed in a separate thrust base.

N. Local Position Indication 1. The display shall be able to be rotated in 90-degree increments in order to provide

easy viewing regardless of actuator mounting position.

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2. The display shall include indicators for: a. Torque overload b. Loss of remote control c. Loss of battery voltage, if motor operator can use batteries d. Failure of actuator

O. Local Control Station 1. Local control stations shall be provided integral to each operator and shall consist of

the following: a. "Local/Computer" two-position selector switch b. "Stop" push-button with lockout feature c. “Open" push-button d. "Close" push-button e. "Open" indicator lamp with red lens f. "Closed" indicator lamp with green lens

2. Provide an extra contact on the two position selector switch which closes in the local position. The additional extra selector switch contact is to be factory-wired in parallel with a "b" (closes when switch opens) auxiliary contact. The "b" auxiliary contact is to be part of a main disconnect module that is integral with the valve assembly.

3. The local controls shall be arranged so that the direction of valve travel can be reversed without the necessity of stopping the actuator. Valve indicator and read out information shall face horizontally toward walkway.

P. Remote Control Facilities 1. Each operator shall be capable of accepting discrete remote control signals from

remote contact closures. 2. Terminals shall be provided to facilitate termination of all field control and status

wiring. 3. Connections for external remote controls fed from external supply of 120 VAC to be

suitable for any one or more of the following methods of control. a. Open, Close, and Stop b. Open and Close c. Overriding Emergency, Shutdown to Close (or Open) Valve from a selectable

“Make” or “Brake” Contact. d. Two-Wire Control, Energize to Close (or Open), De-Energize to Open (or

Close) 4. Selection of maintained or push-to-run control for “Open, Close, and Stop” and

“Open and Close” modes shall be provided. 5. The remote controls shall be arranged so that the direction of valve travel can be

reversed without the necessity of stopping the actuator. 6. Starter contactors shall be protected from excessive current surges during travel

reversal by an automatic time delay on energization of approximately 300 ms. 7. Upon loss of command signal, a choice of "lock in last position, "fail close on lost

signal, or "fail to preset position" via jumper select feature shall be available. 8. The modulating operators shall be capable of positioning the valve in proportion to a

4-20 mAdc input signal. The modulating operators shall include a 4-20 mAdc position transmitter to allow remote position indication.

9. Provide dry contacts for the following signals: a. Valve in remote position b. Valve failure c. Low battery, if motor operator can use batteries d. Valve open status e. Valve closed status. Valve position and valve position command shall be available as analog inputs and outputs respectively.

Q. Monitoring and Diagnostics Facilities 1. Facilities shall be provided for monitoring actuator operation and availability as

follows:

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a. Monitor relay, having one change-over contact, the relay being energized from the control transformer only when the Local/Off/Remote selector is in the Remote position and thermostat is not tripped to indicate that the actuator is available for remote operation.

b. It shall be possible to provide indication of thermostat trip and Remote selected as discreet signals.

R. Integral Starter and Transformer 1. On/Off Service: The reversing starter shall be suitable for 60 starts per hour not to

exceed a rate of 600 starts per hour and a rating appropriate to the motor size. 2. Modulating Service: The actuator shall be of solid state design suitable for 1,200

starts per hour. Full voltage type mechanically and electrically interlocked magnetic reversing motor starter suitable for operation in any mounting position.

3. The controls supply transformer shall have the necessary tappings and be adequately rated to provide power for the following functions:

a. 24V DC output as standard, or alternate 100V AC output, where required for remote controls.

b. Supply for all the internal electrical circuits. 4. Transformer shall be vacuum pressure impregnated with dual voltage primary and

fused secondary.

S. Wiring and Terminals 1. Internal wiring shall be of tropical grade PVC insulated stranded cable of appropriate

size for the control and three phase power. Each wire shall be clearly identified at each end.

2. The terminal compartment of the actuator shall be provided with a minimum of three (3) threaded cable entries.

3. All wiring supplied as part of the actuator shall be contained within the main enclosure for physical and environmental protection. External conduit connections between components are not acceptable.

4. Control logic circuit boards and relay boards must be mounted on plastic mounts to comply with double insulated standards.

5. Durable terminal identification card showing plan of terminals shall be provided and attached to the inside of the terminal box cover indicating:

a. Serial Number b. External Voltage Values c. Wiring Diagram Number d. Terminal Layout

6. The identification card must be suitable for the Contractor to inscribe cable core identification beside terminal numbers.

T. Enclosure 1. Actuator shall be designed for non-intrusive start up and commissioning. 2. Actuators shall be O-ring sealed. 3. Enclosure must allow for site storage without the need for electrical supply

connection. 4. No breather or drain ports shall be utilized so as to maintain housing integrity. There

shall be no need for special conduit connections to maintain NEMA 4X rating. 5. All external fasteners shall be 316 stainless steel.

2.4 SURFACE PREPARATION AND SHOP COATING

A. All surfaces, other than stainless steel or fully UV-resistant plastics, shall be shop coated in accordance with Section 09905 “Painting”.

PART 3 - EXECUTION

3.1 INSTALLATION ASSISTANCE

A. Furnish instructions for installation by CONTRACTOR. Furnish the required oil and grease for initial operation.

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B. Field tests shall not be conducted until such time that the entire installation is complete and ready for testing.

C. A certificate from the equipment manufacturer stating that the installation of this equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and care of each unit shall be submitted.

3.2 TESTING

A. Operators shall be full-load field tested in conjunction with respective gate or valve testing.

B. Manufacturer's field representative shall conduct tests in presence of ENGINEER.

END OF SECTION

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GATES, SLIDE F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15151 GATES, SLIDE.DOCX

SECTION 15151 GATES, SLIDE

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Slide gates, frames, stainless steel construction.

B. Related Sections: 1. Refer to Section 15100 “Valves: Basic requirements and Miscellaneous” for

information regarding submittals; quality assurance; coordination; material delivery, handling, and storage; projection conditions; design requirements; other materials; installation of piping systems; field testing; and related work.

2. Refer to Section 15113 “Electric Motor Operators” for requirements for electric motor operators.

1.3 REFERENCES

A. ASTM International (ASTM): 1. A 126, Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings. 2. A 240, Specification for Chromium and Chromium-Nickel Stainless steel Plate, Sheet,

and Strip for Pressure Vessels and for general Applications. 3. A 276, Specification for Stainless and Heat-Resisting Steel Bars and Shapes. 4. B 584, Specification for Copper Alloy Sand Castings for General Applications. 5. D 2000, Classification System for Rubber Products in Automotive Applications 6. D 4020, Specification for Ultra-High-Molecular-Weight Polyethylene Molding and

Extrusion Materials 7. F 593, Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs 8. F 594, Specification for Stainless Steel Nuts

B. American Water Works Association (AWWA): 1. C 513 – Open Channel, Fabricated-Metal, Slide Gates and Open Channel,

Fabricated-Metal Weir Gates. 2. C 561 – Fabricated Stainless Steel Slide Gates

PART 2 - PRODUCTS

2.1 STAINLESS STEEL SLIDE GATES

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Hydro Gate 2. Waterman 3. Whipps, Inc. 4. Waco

B. General: 1. Gates shall comply with the requirements of AWWA C 561. 2. Gates shall be as specified and have the characteristics and dimensions shown on

the Drawings 3. Leakage shall not exceed 0.05 gpm/ft of wetted seal perimeter in seating head and

unseating head conditions. 4. Gate shall utilize self-adjusting seats.

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5. Structural components of the frame and slide shall be fabricated from stainless steel having a minimum thickness of 1/4-inch and have adequate strength to prevent distortion during normal handling, during installation and while in service.

6. All welds shall be accomplished by welders with AWS certification. 7. Finish:

a. Mill finish on stainless steel. b. Welds to be sandblasted to remove weld burn and scale. c. Iron and steel components shall be prepared, primed and coated with finish

system in accordance with Section 09910 “Painting and Protective Coatings.” 8. Materials:

Components Materials

Frame Assembly and Retainers ASTM A240, ASTM A276, Type 304 or 304L Stainless Steel

Slide and Stiffeners ASTM A240, ASTM A276, Type 304 or 304L Stainless Steel

Stem ASTM A276, Type 304 Stainless Steel Fasteners, Nuts and Bolts ASTM F593 or F594, Type 304 Stainless

Steel Invert Seal (Upward Opening Gates) Neoprene ASTM D2000 or EDPM Seat/Seal and Facing Ultra-High Molecular Weight Polyethylene

ASTM D4020 Lift Nuts Bronze ASTM B584 Pedestal and Wall brackets ASTM A276 Type 304L Stainless Steel Operator Housing Cast aluminum or ductile iron

C. Frame: 1. The frame guides, invert member and yoke members shall be constructed of

extruded aluminum shapes with a minimum thickness of 1/4-inch. a. Frame design shall allow for embedded mounting or mounting directly to a wall

with stainless steel anchor bolts and grout or mounting to a wall thimble with stainless steel mounting studs and a mastic gasket material. Mounting style shall be as shown on the Contract Drawings.

b. Structural portion of frame that incorporates the seat/seals shall be formed into one piece for rigidity.

c. The frame guides shall extend to accommodate the entire height of the slide when the slide is in the fully opened position on upward opening slide gates or downward opening weir gates.

2. Self-contained gates shall be provided with a yoke across the top of the frame guides. The yoke shall be formed by two structural members affixed to the top of the guides to provide a one-piece rigid frame. The yoke shall be designed to allow removal of the slide.

3. Provide a rigid stainless steel invert member across the bottom of the opening and shall be of the flush bottom type on upward opening gates,

4. Provide a rigid extruded aluminum top seal member across the top of the opening on gates designed to cover submerged openings.

D. Slide: 1. The slide and reinforcing stiffeners shall be constructed of stainless steel plate with a

minimum thickness of 1/4-inch. a. The slide shall not deflect more than 1/360 of the span or 1/16 inch, whichever

is smaller, under the maximum design head. b. When the width of the gate opening multiplied by the maximum design head is

80 square feet or greater, the portion of the slide that engages the guide members shall be of a “thick edge” design. The thick edge portion of the slide shall have a minimum thickness of 3 inches.

2. Reinforcing stiffeners shall be welded to the slide and mounted horizontally. Vertical stiffeners shall be welded on the outside of the horizontal stiffeners for additional reinforcement.

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3. The stem connector shall be constructed of two angles or plates. The stem connector shall be welded to the slide. A minimum of two bolts shall connect the stem to the stem connector.

E. Seals: 1. Gates shall be provided with a self-adjusting seal system to restrict leakage in

accordance with the requirements listed in this specification. a. Equipped with UHMW polyethylene seat/seals to restrict leakage and to

prevent metal to metal contact between the frame and slide. b. Seat/seals shall extend to accommodate the 1-1/2 x the height of the slide

when the slide is in the fully closed or fully opened position. 2. Upward opening gates shall be provided with a resilient seal to seal the bottom

portion of the gate. The seal shall be attached to the invert member of the frame or the bottom of the slide.

3. Seals shall be bolted or mechanically fastened to the frame or slide. Arrangements that are force fit or held in place with adhesives are not acceptable. Gates that utilize rubber “J” seals or “P” seals are not acceptable.

4. Seal system shall be durable and shall be designed to accommodate high velocities and frequent cycling without loosening or suffering damage.

5. Seals shall be mounted so as not to obstruct the water way opening. 6. The seal system shall have been factory tested to confirm negligible wear (less than

0.01”) and proper sealing. The factory testing shall consist of an accelerated wear test comprised of a minimum of 25,000 open-close cycles using a well-agitated sand/water mixture to simulate fluidized grit.

F. Stem: 1. A threaded operating stem shall be utilized to connect the operating mechanism to

the slide. a. Rising stem gates, the threaded portion shall engage the operating nut in the

manual operator or motor actuator. b. Non-rising stem gates, the threaded portion shall engage the nut on the slide. c. Threaded portion of the stem shall have a minimum outside diameter of 1-1/2

inches. Stem extension pipes are not acceptable. 2. Construction:

a. Constructed of solid stainless steel bar for the entire length, the metal having a tensile strength of not less than 90,000 psi for stems that are 3 inches or less in diameter. Stems that are in excess of 3 inches in diameter shall have a tensile strength of 85,000 psi.

b. Threaded to allow full travel of the slide unless the travel distance is otherwise shown on the Contract Drawings.

c. Maximum L/R ratio for the unsupported part of the stem shall not exceed 200. d. In compression, the stem shall be designed for a critical buckling load caused

by a 40 lb effort on the crank or handwheel with a safety factor of 2, using the Euler column formula.

e. The stem shall be designed to withstand the tension load caused by the application of a 40 lb effort on the crank or handwheel without exceeding 1/5 of the ultimate tensile strength of the stem material.

f. The threaded portion of the stem shall have machine cut or rolled threads of the full Acme type with a 16 microinch finish or better. Stub threads are not acceptable.

3. Stems of more than one section shall be joined by stainless steel couplings. The coupling shall be bolted to the stems.

4. Stems, on manually operated gates, shall be provided with adjustable stop collars to prevent over closing of the slide.

G. Stem Guides: Stem guide shall be provided when necessary to ensure that the maximum L/R ratio for the unsupported part of the stem is 200 or less. 1. Stem guide brackets shall be constructed of aluminum or stainless steel with a

minimum thickness of 1/4-inch and shall be outfitted with UHMW or bronze bushings. 2. Adjustable in two directions.

H. Wall Thimbles:

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1. Wall thimbles shall be provided when shown on the Contract Drawings. 2. Design:

a. Wall thimble depth shall be equal to the thickness of the concrete wall in which the thimble is to be mounted.

b. Fabricated stainless steel construction of adequate section to withstand all operational and reasonable installation stresses.

c. Constructed of 1/4-inch minimum thickness stainless steel and the front face shall have a minimum thickness of 1/4–inch.

d. Fabrication process shall ensure that the wall thimble is square and plumb and the front face is sufficiently flat to provide a proper mounting surface for the gate frame.

e. Face of the wall thimble shall only be machined if recommended by the gate manufacturer, and shall have a minimum thickness of 1/4-inch after machining.

3. Water Stop: Provide welded around the periphery of the thimble. Wall thimbles shall be designed to allow thorough and uniform concrete placement during installation.

4. Studs and nuts shall be stainless steel. 5. A suitable gasket or mastic shall be provided to seal between the gate frame and the

wall thimble.

2.2 MANUAL OPERATORS

A. Unless otherwise shown on the Drawings, gates shall be operated by a manual handwheel or a manual crank-operated gearbox. The operator shall be mounted on the yoke of self contained gates or on the pedestal of non-self contained gates. 1. Select the proper gear ratio to ensure that the gate can be operated with no more

than a 40 lb effort when the gate is in the closed position and experiencing the maximum operating head.

2. An arrow with the word "OPEN" shall be permanently attached or cast onto the operator to indicate the direction or rotation to open the gate.

3. Handwheel operators shall be fully enclosed and shall have cast aluminum or ductile iron housing. a. Provide a threaded cast bronze lift nut to engage the operating stem. b. Equipped with roller bearings above and below the operating nut. c. Provide mechanical seals above and below the operating nut to exclude

moisture and dirt and prevent leakage of lubricant out of the hoist. d. Handwheel shall be removable and shall have a minimum diameter of 15

inches.

B. Crank-operated gearboxes shall be fully enclosed and shall have cast aluminum or ductile iron housing. 1. Gearboxes shall have either single or double gear reduction depending upon the

lifting capacity required. 2. Gearboxes shall be provided with a threaded cast bronze lift nut to engage the

operating stem. a. Bearings shall be provided above and below the flange on the operating nut to

support both opening and closing thrusts. b. Gears shall be steel with machined cut teeth designed for smooth operation. c. The pinion shaft shall be stainless steel and shall be supported on ball or

tapered roller bearings. d. Provide mechanical seals on the operating nut and the pinion shafts to exclude

moisture and dirt and prevent leakage of lubricant out of the hoist. e. Crank shall be cast aluminum with a revolving nylon grip and removable.

3. Gates having widths in excess of 72 inches and widths greater than twice their height shall be provided with two gearboxes connected by an interconnecting shaft for simultaneous operation. a. Interconnecting shafting shall be constructed of aluminum or stainless steel. b. Flexible couplings shall be provided at each end of the interconnecting shaft. c. One crank shall be provided to mount on the pinion shaft of one of the

gearboxes. 4. An extended operator system utilizing chain and sprockets shall be furnished by the

manufacturer when the centerline of the crank or handwheel, on a non-geared

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operator, is located over 48-in above the operating floor. Chain wheels are not acceptable. a. Provide a removable aluminum or stainless steel cover to enclose chain and

sprockets. b. The extended operator system shall lower the centerline of the pinion shaft to

36-in above the operating floor. c. A handwheel may be utilized in conjunction with a gearbox in lieu of the

extended operator system if the centerline of the pinion shaft is 60-in or less above the operating floor.

5. Pedestals shall be constructed of aluminum or stainless steel. a. Pedestal height shall be such that the handwheel or pinion shaft on the crank-

operated gearbox is located approximately 36-in above the operating floor. b. Wall brackets shall be used to support floor stands where shown on the

Drawings and shall be constructed of aluminum or stainless steel. c. Wall brackets shall be reinforced to withstand in compression at least two times

the rated output of the operator with a 40 lb effort on the crank or handwheel. d. The design and detail of the brackets and anchor bolts shall be provided by the

gate manufacturer and shall be approved by the ENGINEER. The gate manufacturer shall supply the bracket, anchor bolts and accessories as part of the gate assembly.

6. Manual and Electric Motor Operators shall be equipped with fracture-resistant clear butyrate or lexan plastic stem covers. a. The top of the stem cover shall be closed. b. The bottom end of the stem cover shall be mounted in a housing or adapter for

easy field mounting. c. Stem covers shall be complete with indicator markings to indicate gate position.

7. When shown on the Contract Drawings, provide 2 inch square nut with a non-rising stem. a. The square nut shall be constructed of bronze. b. The floor box, if required, shall be constructed of stainless steel or cast iron and

shall be set in the concrete floor above the gate as shown. c. Provide one aluminum or stainless steel T-handle wrench for operation.

2.3 ELECTRIC MOTOR OPERATORS

A. Electric Motor: Motor operator shall comply with the requirements of Section 15113 “Electric Valve and Gate Operators.”

2.4 APPURTENANCES

A. Equipment Identification Plates: A 16-gauge stainless steel identification plate shall be securely mounted on the equipment in a readily visible location. The plate shall bear 1/4-inch die-stamped equipment identification number indicated in this Section and/or on the Drawings.

B. Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 100 pounds shall be provided with lifting lugs

C. Anchor Bolts: Provide template and Type 316 stainless steel anchors in accordance with Section 05501 “Anchor Bolts, Expansion Anchors, and Concrete Inserts” and as shown on the Drawings. Size as required by manufacturer. 1. Quantity and location shall be determined by the gate manufacturer. 2. If epoxy type anchor bolts are provided, the gate manufacturer shall provide the studs

and nuts. 3. Anchor bolts shall have a minimum diameter of 1/2-inch.

D. Initial Supply of Lubricants: Manufacturer shall indicate types, brands, and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment. CONTRACTOR shall provide and install the recommended lubricants and shall comply with all manufacturer recommended procedures.

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A. Factory Tests: 1. Aluminum Gates: Test and inspect assembled slide and weir gates according to

AWWA C562, Section 5 “Verification.” Provide test results. 2. Stainless Steel Gates: Test and inspect assembled slide and weir gates according to

AWWA C561, Section 5 “Verification.” Provide test results.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install all gates and appurtenances in accordance with manufacturers printed instructions.

B. Brace wall fittings internally during placement of concrete. Ensure that fittings are properly aligned and anchored; flanges are flush with concrete face and tapped holes plugged and protected from entry of grout. 1. Set anchor bolts in accordance with approved manufacturers drawings. 2. Gate assemblies shall be installed in a true vertical plane, square and plumb. 3. Fill the void in between the gate frame and the wall with non-shrink grout as shown

on the installation drawing and in accordance with the manufacturer’s recommendations.

C. Provide a mastic gasket between the gate frame and wall thimble (when applicable) in accordance with the manufacturer’s recommendations.

3.2 MANUFACTURER'S SERVICE

A. Provide the service of qualified, factory-trained representative of the manufacturer to check and approve each part of the installation before it is placed in operation. He shall instruct the plant personnel in operation, care and maintenance of all gates and appurtenances and supervise initial operation.

3.3 FIELD TESTS AND ADJUSTMENTS

A. Adjust all parts and components as required to provide correct operation. 1. Each gate shall be cycled to confirm that they operate without binding, scraping, or

distorting. The effort to open and close manual operators shall be measured, and shall not exceed the maximum operating effort specified above.

2. Electric motor actuators shall function smoothly and without interruption.

B. Conduct functional field test of each gate to demonstrate that each part and all components together function correctly. All testing equipment required shall be provided.

C. Perform a field leakage test after installation of the slide gate. 1. Perform all adjustments; lubricate mechanisms; and operate each gate through one

complete cycle. 2. Seating and unseating heads shall be measured from the top surface of the water to

the center of the gate. 3. Each gate shall be water tested by the CONTRACTOR.

D. Allowable Leakage: As specified in applicable Part 2 paragraph.

3.4 SCHEDULE

A. The Slide Gate Schedule after the “END OF SECTION” is part of this Section.

END OF SECTION

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SLIDE GATE SCHEDULE

Tag No. Location Size (Inches) Type(1) Head (feet)(2) Operator(3) Mounting(4) Remarks Seating Unseating

G-671 Plant Water Pump Station

30 x 30 SG 10’-6” 15’-0” M SF

Notes: 1. Type: SG = Slide Gate 2. Head measured from top of water surface to center of gate. 3. Operator: M = Manual, EM = Electric Motor 4. Mounting: CH = Channel Mounting, SF = Surface Mounting WT = Wall Thimble, AL = Aluminum Construction, SS = Stainless Steel Construction, RS = Rising Stem, NRS = Non Rising Stem

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PIPING SYSTEM, HEAT TRACING F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15778 PIPING SYSTEM, HEAT TRACING.DOCX

SECTION 15778 PIPING SYSTEM, HEAT TRACING

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Furnish, install, test and place in operation heat tracing systems as shown on the

Drawings and described herein. 2. Each heat tracing system shall consist of piping heat tracing for freeze prevention with

self-regulating, parallel resistance electric heating cables, control panel(s), and all ap-purtenances for a complete and operating system.

3. Installation, startup, testing, and placing in service assistance. 4. Training of OWNER’s personnel.

B. RELATED WORK 1. See Section 15800 "Piping System, Insulation” for insulation of piping.


A. Design Requirements: 1. The heat tracing system shall be designed as shown in the Drawings.

1.4 SUBMITTALS

A. Product Data: Include rated capacities, operating characteristics, furnished specialties, and accessories for each type of product indicated. 1. Schedule heating capacity, length of cable, spacing, and electrical power requirement

for each electric heating cable required. 2. For each type of control panel, provide manufacturer’s technical data on features, per-

formance, electrical characteristics, ratings, and finishes.

B. Shop Drawings: 1. For electric heating cable, include plans, sections, details, and attachments to other

work. Include the following: a. Wiring Diagrams: Power, signal, and control wiring. b. For control panel or system, see Section 11009 “Common Control Panel Re-

quirements for Equipment.”

C. Field quality-control test reports.

D. Operation and maintenance data.

E. Warranty: Special warranty specified in this Section.


A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

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1.6 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace electric heating cable that fails in materials or workmanship within specified warranty period. 1. Warranty Period: 10 years from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 HEAT TRACING SYSTEM

A. Each heat traced pipe shall have its own independent circuit adequately sized to provide full load as required by manufacturer for length of run to be installed.

B. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. BH Thermal Corporation. 2. Chromalox, Inc.; Wiegard Industrial Division; Emerson Electric Company. 3. Delta-Therm Corporation. 4. Easy Heat Inc. 5. Nelson Heat Trace. 6. Pyrotenax; a division of Tyco Thermal Controls. 7. Raychem; a division of Tyco Thermal Controls. 8. Thermon Manufacturing Co. 9. Trasor Corp.

C. Heating Element: Pair of parallel No. 18 AWG, tinned, stranded copper bus wires embed-ded in crosslinked conductive polymer core, which varies heat output in response to temper-ature along its length. Terminate with waterproof, factory-assembled non-heating leads with connectors at one end, and seal the opposite end watertight. Cable shall be capable of crossing over itself once without overheating.

D. Electrical Insulating Jacket: Flame-retardant polyolefin.

E. Cable Cover: Stainless-steel braid, and polyolefin outer jacket with UV inhibitor.

F. Maximum Operating Temperature (Power On): 150 deg F.

G. Maximum Exposure Temperature (Power Off): 185 deg F.

H. Maximum Operating Temperature: 300 deg F.

I. Capacities and Characteristics:

Normal Pipe Size

(Inches)

Minimum Heat Tape Application Rate

(Watts/Linear Foot) ½ 1.0

3/4 – 1 1.2 1 ½ 1.5

2 1.8 2 1/2 – 3 1.9

4 2.7 6 8

8 – 10 5 (2 strips) 12-14 8 (2 strips)

J. Electrical: 1. Control panels shall be provided with 120/208 VAC, 3-phase, 4-wire power. 2. Heat trace cable and modules shall be 120/208-volt rated. Coordinate with the elec-

trical drawings.

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2.2 HEAT TRACING CONTROL PANEL

A. Control Panel for Freeze Protection: 1. Control panel shall measure the ambient temperature and turn on heat tracing once the

ambient temperature reaches the setpoint. 2. Control panel shall have a minimum of five zones.

B. Features: The control panels shall have the following: 1. Acceptable manufacturers

a. Chromalox B100 b. Or approved equal by named manufacturer in Paragraph 2.1B.

2. Ambient sensing controller. 3. Epoxy coated NEMA 4X 316SS corrosion-resistant enclosure. 4. Network communication ability 5. Hand/Off/Auto selection 6. Cabinet heater 7. Internal power distribution

C. Heat trace controller and all associated equipment shall comply with Division 16 requirements.

2.3 ACCESSORIES

A. Cable Installation Accessories: Fiberglass tape, heat-conductive putty, cable ties, silicone end seals and splice kits, and installation clips all furnished by manufacturer, or as recom-mended in writing by manufacturer.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine surfaces and substrates to receive electric heating cables for compliance with re-quirements for installation tolerances and other conditions affecting performance. 1. Ensure surfaces and pipes in contact with electric heating cables are free of burrs and

sharp protrusions. 2. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. Install electric heating cable across expansion, construction, and control joints according to manufacturer's written recommendations using cable protection conduit and slack cable to allow movement without damage to cable.

B. Electric Heating Cable Installation for Freeze Protection for Piping: 1. Install electric heating cables after piping has been tested and before insulation is in-

stalled. 2. Install electric heating cables according to IEEE 515.1. 3. Install insulation over piping with electric cables according to Section 15800 "Piping

System, Insulation." 4. Install warning tape on piping insulation where piping is equipped with electric heating

cables.

C. Set field-adjustable switches and circuit-breaker trip ranges.

D. Protect installed heating cables, including nonheating leads, from damage.

3.3 CONNECTIONS

A. Ground equipment according to Section 16060 "Grounding."

B. Connect wiring according to Division 16."

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A. Testing: Perform tests after cable installation but before application of coverings such as in-sulation, wall or ceiling construction, or concrete. 1. Test cables for electrical continuity and insulation integrity before energizing. 2. Test cables to verify rating and power input. Energize and measure voltage and cur-

rent simultaneously.

B. Repeat tests for continuity, insulation resistance, and input power after applying thermal in-sulation on pipe-mounting cables.

C. Remove and replace malfunctioning units and retest as specified above.

D. See Division 11 Section 11009 “Common Control Panel Requirements for Equipment” for field quality control for control panels.

END OF SECTION

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PIPING SYSTEM, INSULATION F:\PROJECTS\0523\047-01\2-0 WRK PROD\2-3 SPECS\FINAL\DIVISION 15\15800 PIPING SYSTEM, INSULATION.DOC

SECTION 15800 PIPING SYSTEM, INSULATION

PART 1 - GENERAL



1.2 SUMMARY

A. Section Includes: 1. Insulation Materials:

a. Cellular glass. b. Flexible elastomeric. c. Mineral fiber.

2. Adhesives, mastics, sealants, and tapes. 3. Factory-applied and field-applied jackets.

1.3 SUBMITTALS

A. Product Data: For each type of product indicated.

B. Shop Drawings: 1. Detail application of protective shields, saddles, and inserts at hangers for each type of

insulation and hanger. 2. Detail attachment and covering of heat tracing inside insulation. 3. Detail insulation application at pipe expansion joints for each type of insulation. 4. Detail insulation application at elbows, fittings, flanges, valves, and specialties for each

type of insulation. 5. Detail removable insulation at piping specialties, equipment connections, and access

panels. 6. Detail application of field-applied jackets. 7. Detail application at linkages of control devices. 8. Detail field application for each equipment type.


A. Fire-Test-Response Characteristics: Insulation and related materials shall have fire-test-response characteristics indicated, as determined by testing identical products per ASTM E 84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement material containers, with appropriate markings of applicable testing and inspecting agency. 1. Insulation Installed Indoors: Flame-spread index of 25 or less, and smoke-developed

index of 50 or less. 2. Insulation Installed Outdoors: Flame-spread index of 75 or less, and smoke-developed

index of 150 or less.


A. Deliver insulation, coverings, cements, adhesive, and coatings to site in containers with manufacturer's stamp or label, affixed showing fire hazard indexes of products.

B. Protect insulation against dirt, water, and chemical and mechanical damage. Do not install damaged or wet insulation; remove from project site.

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PART 2 - PRODUCTS

2.1 INSULATION MATERIALS

A. General Requirements: 1. Products shall not contain asbestos, lead, mercury, or mercury compounds. 2. Products that come in contact with stainless steel shall have a leachable chloride

content of less than 50 ppm when tested according to ASTM C 871. 3. Insulation materials for use on austenitic stainless steel shall be qualified as acceptable

according to ASTM C 795. 4. Foam insulation materials shall not use CFC or HCFC blowing agents in the

manufacturing process.

B. Cellular Glass: Inorganic, incombustible, foamed or cellulated glass with annealed, rigid, hermetically sealed cells. 1. Products: Subject to compliance with requirements, available products that may be

incorporated into the Work include, but are not limited to, the following: a. Cell-U-Foam Corporation; Ultra-CUF. b. Pittsburgh Corning Corporation; Foamglas Super K.

2. Block Insulation: ASTM C 552, Type I. 3. Special-Shaped Insulation: ASTM C 552, Type III. 4. Board Insulation: ASTM C 552, Type IV. 5. Preformed Pipe Insulation with Factory-Applied ASJ-SSL: Comply with ASTM C 552,

Type II, Class 2. 6. Factory fabricated shapes according to ASTM C 450 and ASTM C 585.

C. Flexible Elastomeric: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials and Type II for sheet materials. 1. Products: Subject to compliance with requirements, available products that may be

incorporated into the Work include, but are not limited to, the following: a. Aeroflex USA Inc.; Aerocel. b. Armacell LLC; AP Armaflex. c. RBX Corporation; Insul-Sheet 1800 and Insul-Tube 180.

D. Mineral-Fiber, Preformed Pipe Insulation: 1. Products: Subject to compliance with requirements, available products that may be

incorporated into the Work include, but are not limited to, the following: a. Fibrex Insulations Inc.; Coreplus 1200. b. Johns Manville; Micro-Lok. c. Knauf Insulation; 1000 Pipe Insulation. d. Manson Insulation Inc.; Alley-K. e. Owens Corning; Fiberglas Pipe Insulation.

2. Type I, 850 deg F Materials: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 547, Type I, Grade A, with factory-applied ASJ-SSL.

2.2 INSULATING CEMENTS

A. Mineral-Fiber, Hydraulic-Setting Insulating and Finishing Cement: Comply with ASTM C 449/C 449M.

2.3 ADHESIVES

A. Materials shall be compatible with insulation materials, jackets, and substrates and for bonding insulation to itself and to surfaces to be insulated. Adhesive shall be as recommended by the supplier of the insulation and jacket materials.

2.4 MASTICS

A. Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL-C-19565C, Type II, and as recommended by insulation supplier.

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B. Vapor-Barrier Mastic: Water based; suitable for indoor and outdoor use on below ambient services. 1. Water-Vapor Permeance: ASTM E 96, Procedure B, 0.013 perm at 43-mil dry film

thickness. 2. Service Temperature Range: Minus 20 to plus 180 deg F. 3. Solids Content: ASTM D 1644, 59 percent by volume and 71 percent by weight. 4. Color: White.

2.5 SEALANTS

A. Joint Sealants: 1. Joint sealants shall be as recommended by pipe insulation supplier and the Materials

shall be compatible with insulation materials, jackets, and substrates. 2. Permanently flexible, elastomeric sealant. 3. Service Temperature Range: Minus 100 to plus 300 deg F. 4. Color: White or gray.

B. ASJ Flashing Sealants, and Vinyl, PVDC, and Aluminum Jacket Flashing Sealants: 1. Materials shall be compatible with insulation materials, jackets, and substrates. 2. Fire- and water-resistant, flexible, elastomeric sealant. 3. Service Temperature Range: Minus 40 to plus 250 deg F. 4. Color: White.

2.6 FACTORY-APPLIED JACKETS

A. Insulation system schedules indicate factory-applied jackets on various applications. When factory-applied jackets are indicated, comply with the following: 1. ASJ: White, kraft-paper, fiberglass-reinforced scrim with aluminum-foil backing;

complying with ASTM C 1136, Type I. 2. ASJ-SSL: ASJ with self-sealing, pressure-sensitive, acrylic-based adhesive covered by

a removable protective strip; complying with ASTM C 1136, Type I.

2.7 FIELD-APPLIED JACKETS

A. Field-applied jackets shall comply with ASTM C 921, Type I, unless otherwise indicated.

B. Aluminum Jacket: Comply with ASTM B 209, Alloy 3003, 3005, 3105 or 5005, Temper H-14. 1. Minimum Thickness:

a. Outdoors: 0.024 inches. b. Indoors: 0.016

2. Finish: Stucco-embossed. 3. Moisture Barrier for Indoor Applications: 1-mil- thick, heat-bonded polyethylene and

Kraft paper. 4. Moisture Barrier for Outdoor Applications: 3-mil- thick, heat-bonded polyethylene and

Kraft paper or 2.5-mil- thick Polysurlyn. 5. Factory-Fabricated Fitting Covers:

a. Same material, finish, and thickness as jacket. b. Preformed 2-piece or gore, 45- and 90-degree, short- and long-radius elbows. c. Tee covers. d. Flange and union covers. e. End caps. f. Beveled collars. g. Valve covers. h. Field fabricate fitting covers only if factory-fabricated fitting covers are not

available.

C. Underground Direct-Buried Jacket: 125-mil- thick vapor barrier and waterproofing membrane consisting of a rubberized bituminous resin reinforced with a woven-glass fiber or polyester scrim and laminated aluminum foil.

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2.8 ACCESSORIES

A. Tapes supplied with products per manufacturers recommendations.

B. Securements: Aluminum bands, insulations pins and hangers, staples, wire, corner angles and related components supplied with products per manufacturers recommendations.

PART 3 - EXECUTION

3.1 PREPARATION

A. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application.

B. Coordinate insulation installation with the trade installing heat tracing. Comply with requirements for heat tracing that applies to insulation.

C. Mix insulating cements with clean potable water; if insulating cements are to be in contact with stainless-steel surfaces, use demineralized water.

3.2 GENERAL INSTALLATION REQUIREMENTS

A. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of equipment and piping including fittings, valves, and specialties.

B. Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses required for each item of equipment and pipe system as specified in insulation system schedules.

C. Install accessories compatible with insulation materials and suitable for the service. Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state.

D. Install insulation with longitudinal seams at top and bottom of horizontal runs.

E. Install multiple layers of insulation with longitudinal and end seams staggered.

F. Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties.

G. Keep insulation materials dry during application and finishing.

H. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer.

I. Install insulation with least number of joints practical.

J. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic. 1. Install insulation continuously through hangers and around anchor attachments. 2. For insulation application where vapor barriers are indicated, extend insulation on

anchor legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic.

3. Install insert materials and install insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by insulation material manufacturer.

4. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over jacket, arranged to protect jacket from tear or puncture by hanger, support, and shield.

K. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses.

L. Install insulation with factory-applied jackets as follows: 1. Draw jacket tight and smooth.

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2. Cover circumferential joints with 3-inch- wide strips, of same material as insulation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip, spaced 4 inches o.c.

3. Overlap jacket longitudinal seams at least 1-1/2 inches. Install insulation with longitudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 2 inches o.c. a. For below ambient services, apply vapor-barrier mastic over staples.

4. Cover joints and seams with tape as recommended by insulation material manufacturer to maintain vapor seal.

5. Where vapor barriers are indicated, apply vapor-barrier mastic on seams and joints and at ends adjacent to pipe flanges and fittings.

M. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness.

N. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement.

O. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches beyond damaged areas. Adhere, staple, and seal patches similar to butt joints.

P. For above ambient services, do not install insulation to the following: 1. Vibration-control devices. 2. Testing agency labels and stamps. 3. Nameplates and data plates. 4. Manholes. 5. Handholes. 6. Cleanouts.

3.3 PENETRATIONS

A. Insulation Installation at Roof Penetrations: Install insulation continuously through roof penetrations. 1. Seal penetrations with flashing sealant. 2. For applications requiring only indoor insulation, terminate insulation above roof surface

and seal with joint sealant. For applications requiring indoor and outdoor insulation, install insulation for outdoor applications tightly joined to indoor insulation ends. Seal joint with joint sealant.

3. Extend jacket of outdoor insulation outside roof flashing at least 2 inches below top of roof flashing.

4. Seal jacket to roof flashing with flashing sealant.

B. Insulation Installation at Underground Exterior Wall Penetrations: Terminate insulation flush with sleeve seal. Seal terminations with flashing sealant.

C. Insulation Installation at Aboveground Exterior Wall Penetrations: Install insulation continuously through wall penetrations. 1. Seal penetrations with flashing sealant. 2. For applications requiring only indoor insulation, terminate insulation inside wall surface

and seal with joint sealant. For applications requiring indoor and outdoor insulation, install insulation for outdoor applications tightly joined to indoor insulation ends. Seal joint with joint sealant.

3. Extend jacket of outdoor insulation outside wall flashing and overlap wall flashing at least 2 inches.

4. Seal jacket to wall flashing with flashing sealant.

D. Insulation Installation at Interior Wall and Partition Penetrations (That Are Not Fire Rated): Install insulation continuously through walls and partitions.

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E. Insulation Installation at Fire-Rated Wall and Partition Penetrations: Install insulation continuously through penetrations of fire-rated walls and partitions.

F. Insulation Installation at Floor Penetrations: 1. Pipe: Install insulation continuously through floor penetrations. 2. Seal penetrations through fire-rated assemblies.

3.4 GENERAL PIPE INSULATION INSTALLATION

A. Requirements in this article generally apply to all insulation materials except where more specific requirements are specified in various pipe insulation material installation articles.

B. Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions: 1. Install insulation over fittings, valves, strainers, flanges, unions, and other specialties

with continuous thermal and vapor-retarder integrity, unless otherwise indicated. 2. Do not insulate flexible pipe couplings and expansion joints. 3. Insulate pipe elbows using preformed fitting insulation or mitered fittings made from

same material and density as adjacent pipe insulation. Each piece shall be butted tightly against adjoining piece and bonded with adhesive. Fill joints, seams, voids, and irregular surfaces with insulating cement finished to a smooth, hard, and uniform contour that is uniform with adjoining pipe insulation.

4. Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of same material and thickness as used for adjacent pipe. Cut sectional pipe insulation to fit. Butt each section closely to the next and hold in place with tie wire. Bond pieces with adhesive.

5. Insulate valves using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. For valves, insulate up to and including the bonnets, valve stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with insulating cement.

6. Insulate strainers using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulating cement. Insulate strainers so strainer basket flange or plug can be easily removed and replaced without damaging the insulation and jacket. Provide a removable reusable insulation cover. For below ambient services, provide a design that maintains vapor barrier.

7. Insulate flanges and unions using a section of oversized preformed pipe insulation. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker.

8. Cover segmented insulated surfaces with a layer of finishing cement and coat with a mastic. Install vapor-barrier mastic for below ambient services and a breather mastic for above ambient services. Reinforce the mastic with fabric-reinforcing mesh. Trowel the mastic to a smooth and well-shaped contour.

9. For services not specified to receive a field-applied jacket except for flexible elastomeric and polyolefin, install fitted aluminum cover over elbows, tees, strainers, valves, flanges, and unions. Terminate ends with aluminum end caps. Tape aluminum covers to adjoining insulation facing using aluminum tape.

10. Stencil or label the outside insulation jacket of each union with the word "UNION." Match size and color of pipe labels.

C. Insulate instrument connections for thermometers, pressure gages, pressure temperature taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes, vessels, and equipment. Shape insulation at these connections by tapering it to and around the connection with insulating cement and finish with finishing cement, mastic, and flashing sealant.

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D. Install removable insulation covers at locations indicated. Installation shall conform to the following: 1. Make removable flange and union insulation from sectional pipe insulation of same

thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe insulation.

2. When flange and union covers are made from sectional pipe insulation, extend insulation from flanges or union long at least two times the insulation thickness over adjacent pipe insulation on each side of flange or union. Secure flange cover in place with stainless-steel or aluminum bands. Select band material compatible with insulation and jacket.

3. Construct removable valve insulation covers in same manner as for flanges except divide the two-part section on the vertical center line of valve body.

4. When covers are made from block insulation, make two halves, each consisting of mitered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached insulation, to flanges with tie wire. Extend insulation at least 2 inches over adjacent pipe insulation on each side of valve. Fill space between flange or union cover and pipe insulation with insulating cement. Finish cover assembly with insulating cement applied in two coats. After first coat is dry, apply and trowel second coat to a smooth finish.

5. Finish exposed surfaces with an aluminum jacket.

3.5 CELLULAR-GLASS INSULATION INSTALLATION

A. Insulation Installation on Straight Pipes and Tubes: 1. Secure each layer of insulation to pipe with wire or bands and tighten bands without

deforming insulation materials. 2. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions

with vapor-barrier mastic and joint sealant. 3. For insulation with factory-applied jackets on above ambient services, secure laps with

outward clinched staples at 6 inches o.c. 4. For insulation with factory-applied jackets on below ambient services, do not staple

longitudinal tabs but secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant.

B. Insulation Installation on Pipe Flanges: 1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice

the thickness of pipe insulation. 3. Fill voids between inner circumference of flange insulation and outer circumference of

adjacent straight pipe segments with cut sections of cellular-glass block insulation of same thickness as pipe insulation.

4. Install jacket material with manufacturer's recommended adhesive, overlap seams at least 1 inch, and seal joints with flashing sealant.

C. Insulation Installation on Pipe Fittings and Elbows: 1. Install preformed sections of same material as straight segments of pipe insulation

when available. Secure according to manufacturer's written instructions. 2. When preformed sections of insulation are not available, install mitered sections of

cellular-glass insulation. Secure insulation materials with wire or bands.

D. Insulation Installation on Valves and Pipe Specialties: 1. Install preformed sections of cellular-glass insulation to valve body. 2. Arrange insulation to permit access to packing and to allow valve operation without

disturbing insulation. 3. Install insulation to flanges as specified for flange insulation application.

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3.6 FLEXIBLE ELASTOMERIC INSULATION INSTALLATION

A. Seal longitudinal seams and end joints with manufacturers recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

B. Insulation Installation on Pipe Flanges: 1. Install pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice


adjacent straight pipe segments with cut sections of sheet insulation of same thickness as pipe insulation.

4. Secure insulation to flanges and seal seams with manufacturers recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

C. Insulation Installation on Pipe Fittings and Elbows: 1. Install mitered sections of pipe insulation. 2. Secure insulation materials and seal seams with manufacturer's recommended

adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

D. Insulation Installation on Valves and Pipe Specialties: 1. Install preformed valve covers manufactured of same material as pipe insulation when

available. 2. When preformed valve covers are not available, install cut sections of pipe and sheet

insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.

3. Install insulation to flanges as specified for flange insulation application. 4. Secure insulation to valves and specialties and seal seams with manufacturer's

recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated.

3.7 MINERAL-FIBER INSULATION INSTALLATION

A. Insulation Installation on Straight Pipes and Tubes: 1. Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten

bands without deforming insulation materials. 2. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions

with vapor-barrier mastic and joint sealant. 3. For insulation with factory-applied jackets on above ambient surfaces, secure laps with

outward clinched staples at 6 inches (150 mm) o.c. 4. For insulation with factory-applied jackets on below ambient surfaces, do not staple

longitudinal tabs but secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant.

B. Insulation Installation on Pipe Flanges: 1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice


adjacent straight pipe segments with mineral-fiber blanket insulation. 4. Install jacket material with manufacturer's recommended adhesive, overlap seams at

least 1 inch (25 mm), and seal joints with flashing sealant.

C. Insulation Installation on Pipe Fittings and Elbows: 1. Install preformed sections of same material as straight segments of pipe insulation

when available.

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2. When preformed insulation elbows and fittings are not available, install mitered sections of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire or bands.

D. Insulation Installation on Valves and Pipe Specialties: 1. Install preformed sections of same material as straight segments of pipe insulation

when available. 2. When preformed sections are not available, install mitered sections of pipe insulation to

valve body. 3. Arrange insulation to permit access to packing and to allow valve operation without

disturbing insulation. 4. Install insulation to flanges as specified for flange insulation application.

3.8 FIELD-APPLIED JACKET INSTALLATION

A. Install with 2-inch overlap at longitudinal seams and end joints. Overlap longitudinal seams arranged to shed water. Seal end joints with weatherproof sealant recommended by insulation manufacturer. Secure jacket with stainless-steel bands 12 inches o.c. and at end joints. 1. Install aluminum jackets on exterior above grade piping and fittings and on interior

piping insulated using cellular-glass.

3.9 FINISHES

A. Do not field paint aluminum or stainless-steel jackets.

3.10 PIPING INSULATION SCHEDULE

A. General Requirements: 1. Acceptable preformed pipe and tubular insulation materials and thicknesses are

identified for each piping system and pipe size range. If more than one material is listed for a piping system, selection from materials listed is Contractor's option.

2. All exposed outdoor piping and piping installed in unheated vaults, 8 inches in diameter and smaller (Unless otherwise indicted on the Drawings) shall be insulated.

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PIPE INSULATION SCHEDULE

Flowstream Pipe Diameter (Inches)

Insulation Thickness (Inches) Insulation Type(3)

Indoor Outdoor(2)

Instrument Sensing Lines(1)

---- NA

Domestic Hot Water 3/4 3/4 Flexible Elastomeric Domestic Cold Water 1 Flexible Elastomeric Water and Waste Water

Less than 2 NA 1-1/2 Cellular-glass Mineral Fiber

Water and Waste Water

2 to 6 NA 2 Cellular-glass Mineral Fiber

Water and Waste Water

8 to 12 NA 2 Cellular-glass Mineral Fiber

Vent, Air Release 1 to 2 NA 1 Flexible Elastomeric Mineral Fiber

Blower Air Piping(4) Mineral Fiber Sample 1/2 to 1 NA 3/4 Flexible Elastomeric 1. Instrument sense lines include tubing used for differential pressure measurements in venture flow meters, pressure indicating devices, and other instruments. 2. Outdoor includes piping exposed to atmosphere; areas inside unheated vaults, utility corridors, chases, etc. 3. When more than one insulation type named Contractor may select. 4. Apply insulation to hot blower discharge piping in accessible areas for personnel protection.

B. Heat Trace: 1. Provide heat tracing in accordance with Section 15778 “Piping System, Heat Tracing.” 2. Size insulation to accommodate heat tracing cable

3.11 INDOOR, FIELD-APPLIED JACKET SCHEDULE

A. Install jacket over insulation material. For insulation with factory-applied jacket, install the field-applied jacket over the factory-applied jacket. 1. Piping, Concealed:

a. None. 2. Piping, Exposed:

a. Aluminum, Stucco Embossed: 0.016 inch thick.

3.12 OUTDOOR, FIELD-APPLIED JACKET SCHEDULE

A. Install jacket over insulation material. For insulation with factory-applied jacket, install the field-applied jacket over the factory-applied jacket. If more than one material is listed, selection from materials listed is Contractor's option.

B. Piping: 1. Aluminum, Stucco Embossed with Z-Shaped Locking Seam: 0.024 inch thick.

END OF SECTION

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ELECTRICAL – GENERAL PROVISONS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16000 ELECTRICAL GENERAL PROVISIONS.DOCX

SECTION 16000 ELECTRICAL - GENERAL PROVISIONS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials and equipment required to install, test and provide an operational, electrical system as specified and as shown on the Drawings.

B. All equipment described herein shall be submitted and furnished as an integral part of equipment specified elsewhere in these Specifications.

C. All electrical work provided under any Division of the Specifications shall fully comply with the requirements of Division 16.

D. The work shall include furnishing, installing and testing the equipment and materials detailed in each Section of Division 16,

E. The work shall include furnishing and installing the following: 1. This project consists of making modifications to existing motor control centers and other

existing power distribution equipment. No new service from an electrical utility is required.

2. Provide a complete raceway system, wire and field connections for all motors, motor controllers, control devices, control panels and electrical equipment furnished under other Divisions. The Contractor shall coordinate his construction schedule and electrical interface with the supplier of electrical equipment specified under other Divisions as required by the Contract Documents.

3. Provide a complete raceway system, wiring and terminations for all field-mounted instruments furnished and mounted under other Divisions, including process instrumentation primary elements, transmitters, local indicators and control panels. Lightning and surge protection equipment wiring at process instrumentation transmitters. Install vendor furnished cables specified under other Divisions as required by the Contract Documents.

4. Provide a complete raceway system for the Data Cables and specialty cable systems, including those furnished under other Divisions. Install the Data Cables and other specialty cable systems, in accordance with the system manufacturers' installation instructions. Review the raceway layout, prior to installation, with the Process Control System supplier and the cable manufacturer to ensure raceway compatibility with the systems and materials being furnished. Where redundant cables are furnished, install the cables in separate raceways as required by the Contract Documents.

5. The Contractor may re-use existing concealed raceways as indicated on the drawings. The Engineer has, to the extent possible by observation, has indicated the presence of concealed raceways which may be used, however the responsibility to verify those raceways lies entirely with the Contractor, who shall field verify their usability prior to bidding. Should the indicated raceways not be usable, then the Contractor shall provide exposed or concealed raceways to provide a complete raceway system with no change in contract price permitted.

6. The Contractor may reuse exposed raceways with modifications and and extensions as required to provide a complete raceway system as specified. Exposed raceways which are to be reused may only be reused if the meet the raceway specifications in the type and material specified for new raceways.

7. Modifications to existing control systems including installation of auxiliary motor starter contacts, relays, switches, etc., as required to provide the control functions or inputs as shown on the Drawings or as specified in the Contract Documents. Obtain the existing equipment shop drawings from the Owner, or information not shown on existing Drawings, before attempting to make any modifications to the existing equipment wiring.

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Verify all existing wiring and connections for correctness. If record drawings are not available, trace all circuits in the field and develop the wiring diagrams necessary for completion of the work. Document all changes made to the wiring diagrams and return a marked-up set of Record Drawings to the Owner after the work is complete.

8. Coordinate the sequence of demolition with the sequence of construction to maintain plant operation in each area. Remove and demolish equipment and materials in such a sequence that the existing and proposed plant will function properly with no disruption of treatment.

9. Make modifications to existing motor control centers, switchboards, panelboards and motor controllers including installation of circuit breakers, etc., or disconnection of circuits as required to provide the power supplies to new and existing equipment to maintain the plant in operation.

10. All bidders shall visit the site of the project, prior to submitting a bid, and satisfy themselves as to any question that they might have, relating to existing raceways, equipment, condition or construction.

11. The Contractor shall provide standby generation to keep the Owner’s process in service as required by the Contract Documents.

12. New raceways or modified existing raceways shall be routed such that they do not block access to any enclosures or equipment that would interfere with replacement or maintenance, nor shall raceways block doors or windows or be installed such that they present any hazard or nuisance to the Owner’s staff for egress, operation or maintenance.

13. Provide all new conductors, cables, fiber optics cables in every instance. Under no circumstance shall any conductors be reused without express permission from the Engineer and Owner on a case by case basis.

14. Where equipment is shown or specified to be removed and replaced or demolished, the Contractor shall remove all associated exposed conduits back to their source or to the point of entrance to a concealed portion where the conduits are inaccessible. At the point of entry to a concealed portion, the conduits shall be capped and tagged with their destination point. The Contractor’s conformed to construction record drawings shall clearly show all concealed conduits which are still usable and indicate the location of each end along with the tag designation that was placed on the concealed raceway. Exposed raceways passing through walls shall be removed and the hole patched and painted to match the existing structure. Exposed raceways which enter existing wire ways which are remaining shall have the holes plugged in a manner to maintain the NEMA rating of the wire way. All conductors which are associated with equipment shown to be demolished shall be completelyremoved from the raceway system back to their source.

F. Provide all electrical relocation work associated with the relocation of equipment for the existing and new facilities, including disconnecting all existing wiring and conduits and providing new wiring and conduit to the relocated equipment as specified in Section 16060.

G. The Contractor is responsible to maintain the Owner’s process operations during all construction including any required electrical or control system outages. The Contractor shall obtain all needed process operational requirements and restrictions from the Owner’s staff during the site visits to determine the effect the operational restrictions may have on the construction schedule and/or bid price. The information is required to be obtained by the Contractor prior to bidding. The contractor is required to verify any process related information which may be shown or specified. If the Owner’s information conflicts with information in the Contract Documents, the Contractor shall notify the Engineer in writing prior to bidding. As a minimum, the Contractor shall include in the Contract Schedule and Bid Price the following items required to comply with operational requirements:

1. Additional Time and/or Expense 2. Additional Expense for after-hours work, 3. Additional equipment, materials, and personnel.

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4. Standby generation with fuel.

H. The Bid Price shall be in complete compliance with the Contact Documents. Any exception shall be included in the bid with a detailed explanation that clearly indicates the paragraph of this Specification and / or the item in the Drawings to which the exception applies. The Contractor shall explain in detail the reasons for the exception. The inclusion of an exception and its explanation as specified shall not constitute any obligation on the part of the Engineer / Owner to accept the Bid Price with the exception.

I. This Specification shall have precedence over any conflict in the bidders submittals and / or descriptive information and the Contract Documents unless an exception is made at the time of bidding as specified herein, and the bid price is accepted with the bidder’s exception by the Engineer / Owner.

J. The Contractor shall provide all tools, equipment, supplies, and shall perform all labor required to install the equipment specified in the Contract Documents in order to install, test, and place into satisfactory operation in the time specified for completion in the Contract Documents. Failure of any of the Contractors sub-contractors or suppliers to perform the work as specified shall not constitute an acceptable reason for the Owner to grant any change in the Contract Price or additions to the Contract Time.

1.2 ELECTRICAL WORK CONTAINED IN OTHER DIVISIONS

A. Where references are made to the Related Work paragraph in each Specification Section, referring to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

B. Process Divisions 1. The Contractor shall be responsible for examining all Process Equipment Specifications

and Drawings, determining power and wiring requirements and providing external wiring and raceways, as required providing a fully functioning Process Control System. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, at no cost to the Owner.

C. Mechanical Divisions 1. The Contractor shall be responsible for examining all Mechanical Equipment

Specifications and Drawings, determining power and wiring requirements and providing external wiring and raceways, as required providing fully functioning Mechanical Equipment Control Systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring at no cost to the Owner.

1.3 SUBMITTALS

A. Submit Shop Drawings, in accordance with Division 1 requirements, for equipment, materials and all other items furnished under each Section of Division 16, except where specifically stated otherwise. An individually packaged submittal shall be made for each Section, and shall contain all of the information required by the Section. Partial submittals will not be accepted and will be returned without review.

B. Submittals will not be accepted for Section 16000.

C. Each Section submittal shall be complete, contain all of the items listed in the Specification Section, and shall be clearly marked to indicate which items are applicable on each cut sheet page. The Submittal shall list any exceptions to the Specifications and Drawings, and the reason for such deviation. Shop drawings, not so checked and noted, will be returned without review.

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D. The Contractor shall check shop drawings for accuracy and contract requirements prior to submittal to the Owner/Engineer. Errors and omissions on approved shop drawings shall not relieve the Contractor from the responsibility of providing materials and workmanship required by the Specifications and Drawings. Shop drawings shall be stamped with the date checked and a statement indicating that the shop drawings conform to Specifications and Drawings. Only one Specification Section may be made per transmittal.

E. Material shall not be ordered or shipped until the shop drawings have been approved. No material shall be ordered or shop work started if shop drawings are marked "APPROVED AS NOTED CONFIRM", "APPROVED AS NOTED RESUBMIT" or "NOT APPROVED".

F. At the time of jobsite delivery of the equipment, the Contractor shall have an approved shop drawing in his possession for the Owner’s Inspector and Owner’s Engineer, for verification.

G. Up-to-date Record Drawings shall be promptly furnished when the equipment installation is complete. Payment will be withheld until Record Drawings have been furnished and approved.

H. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. Electric equipment, materials and installation shall comply with the National Electrical Code (NEC) and with the latest edition of the following codes and standards:

1. National Electrical Safety Code (NESC) 2. Occupational Safety and Health Administration (OSHA) 3. National Fire Protection Association (NFPA) 4. National Electrical Manufacturers Association (NEMA) 5. American National Standards Institute (ANSI) 6. Insulated Cable Engineers Association (ICEA) 7. Instrument Society of America (ISA) 8. Underwriters Laboratories (UL) 9. Factory Mutual (FM) 10. City of Flower Mound, Texas, Electrical Code


C. All material and equipment, for which a UL standard exists, shall bear a UL label. No such material or equipment shall be brought onsite without the UL label affixed.

D. If the issue of priority is due to a conflict or discrepancy between the provisions of the Contract Documents and any referenced standard, or code of any technical society, organization or association, the provisions of the Contract Documents will take precedence if they are more stringent or presumptively cause a higher level of performance. If there is any conflict or discrepancy between standard specifications, or codes of any technical society, organization or association, or between Laws and Regulations, the higher performance requirement shall be binding on the Contractor, unless otherwise directed by the Owner/Engineer.

E. In accordance with the intent of the Contract Documents, the Contractor accepts the fact that compliance with the priority order specified shall not justify an increase in Contract Price or an extension in Contract Time nor limit in any way, the Contractor's responsibility to comply with all Laws and Regulations at all times

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1.5 AREA CLASSIFICATION INCLUDING HAZARDOUS AREAS

A. Equipment, materials and installation in areas designated as hazardous on the Drawings shall comply with NEC Articles 500, 501, 502 and 503. Area classifications in wastewater plants shall be determined by the requirements of NFPA 820, the design engineer and finally by the Authority Having Jurisdiction.

B. Equipment and materials installed in hazardous areas shall be UL listed for the appropriate hazardous area classification.

C. All areas indoors, outdoors, above and below grade are to be considered, at a minimum, wet, and corrosive requiring NEMA 4X rated enclosures, unless classified hazardous in accordance with the preceding paragraphs in this section. Exceptions are indoor dry electrical rooms, control rooms and office spaces.

1.6 CODES, INSPECTION AND FEES

A. Equipment, materials and installation shall comply with the requirements of the local authority having jurisdiction.

B. Obtain all necessary permits and pay all fees required for permits and inspections.

1.7 SIZE OF EQUIPMENT

A. Investigate each space in the structure through which equipment must pass to reach its final location. Coordinate shipping splits with the manufacturer to permit safe handling and passage through restricted areas in the structure.

B. The equipment shall be kept upright at all times during storage and handling. When equipment must be tilted for passage through restricted areas, brace the equipment to ensure that the tilting does not impair the functional integrity of the equipment.

1.8 RECORD DRAWINGS

A. As the work progresses, legibly record all field changes on a set of Project Contract Drawings, hereinafter called the "Record Drawings". The Record Drawings and Specifications shall be kept up to date throughout the project.

B. The Record Drawings shall be reviewed in a meeting with the Owner/Engineer on a monthly basis.

C. Record Drawings shall accurately show the installed condition of the following items: 1. One-line Diagram(s). 2. Raceways and pull boxes. 3. Conductor sizes and conduit fills. 4. Panel Schedule(s). 5. Control Wiring Diagram(s). 6. Lighting Fixture Schedule(s). 7. Lighting fixture, receptacle and switch outlet locations. 8. Underground raceway and duct bank routing. The drawings shall include the measured

width and height of the duct bank, and shall survey the elevation of the top of the duct bank or record its depth of burial below grade at intervals not to exceed 50 feet along the entire length. Changes in direction between termination points shall be surveyed and recorded on the record drawings.

9. Plan view, measured dimensions and locations of switchgear, distribution transformers, substations, motor control centers and panelboards.

10. Modifications to controls systems or any piece of electrical equipment including field-verified existing controls and all changes clearly identified.

D. Submit a typical example of a schedule of control wiring raceways and wire numbers, including the following information:

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1. Circuit origin, destination and wire numbers. 2. Field wiring terminal strip names and numbers.

E. As an alternate, submit a typical example of point-to-point connection diagrams showing the same information, may be submitted in place of the schedule of control wiring raceways and wire numbers.

F. Submit the record drawings and the schedule of control wiring raceways and wire numbers (or the point-to-point connection diagram) to the Owner/Engineer.

G. The Contractor’s retainage shall not be paid until the point-to-point connection diagrams have been furnished to the Owner/Engineer.

1.9 EQUIPMENT INTERCONNECTIONS

A. Review shop drawings of equipment furnished under other related Divisions and prepare coordinated wiring interconnection diagrams or wiring tables. Submit copies of wiring diagrams or tables with Record Drawings.

B. Furnish and install all equipment interconnections.


A. Materials and equipment shall be new, except where specifically identified on the Drawings to be re-used.

B. The Contractor shall not bring onsite, material or equipment from a manufacturer, not submitted and approved for this project. Use of any such material or equipment, will be rejected, removed and replaced by the Contractor, with the approved material and equipment, at his own expense.

C. Material and equipment shall be UL listed, where such listing exists.

D. The Contractor shall be responsible for all material, product, equipment and workmanship being furnished by him for the duration of the project. He shall replace the equipment if it does not meet the Contract Documents.


A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner/Engineer upon delivery of the equipment, an approved copy of all such submittals. Delivery of incomplete constructed equipment, or equipment which failed any factory tests, will not be permitted.

B. Equipment and materials shall be handled and stored in accordance with the manufacturer’s instructions, and as specified in the individual Specification Sections.

1.12 WARRANTIES

A. Manufacturer’s warranties shall be as specified in each of the Specification Sections.

1.13 EQUIPMENT IDENTIFICATION

A. Identify equipment (disconnect switches, separately mounted motor starters, control stations, etc.) furnished under Division 16 with the name of the equipment it serves. Motor control centers, control panels, panelboards, switchboards, switchgear, junction or terminal boxes, transfer switches, etc, shall have nameplate designations as shown on the Drawings.

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PART 3 - EXECUTION

3.1 INTERPRETATION OF DRAWINGS

A. The Drawings are not intended to show exact locations of conduit runs. Coordinate the conduit installation with other trades and the actual supplied equipment.

B. Install each 3 phase circuit in a separate conduit unless otherwise shown on the Drawings.

C. Unless otherwise approved by the Owner/Engineer, conduit shown exposed shall be installed exposed; conduit shown concealed shall be installed concealed. The Contractor shall submit a Request for Information for any conduit route which is not clearly identified as concealed or exposed in the Contract Documents prior to its installation.

D. Where circuits are shown as "home-runs" all necessary fittings and boxes shall be provided for a complete raceway installation.

E. Verify the exact locations and mounting heights of lighting fixtures, switches and receptacles prior to installation.

F. Except where dimensions are shown, the locations of equipment, fixtures, outlets and similar devices shown on the Drawings are approximate only. Exact locations shall be determined by the Contractor and approved by the Owner/Engineer during construction. Obtain information relevant to the placing of electrical work and in case of any interference with other work, proceed as directed by the Owner/Engineer and furnish all labor and materials necessary to complete the work in an approved manner.

G. Circuit layouts are not intended to show the number of fittings, exact routing or other installation details. Exposed conduit routings are shown to indicate the presence of the raceway not its exact route. Not all raceways are shown on the plan views. Other raceway requirements are shown on one line diagrams, raiser diagrams and interface wiring diagrams. Where ever the need for circuits and raceways are indicated, the contractor shall provide them and field route from source to load in the manner specified. Furnish all labor and materials necessary to install and place in satisfactory operation all power, lighting and other electrical systems shown.

H. Redesign of electrical or mechanical work, which is required due to the Contractor's use of a pre-approved alternate item, arrangement of equipment and/or layout other than specified herein, shall be done by the Contractor at his/her own expense. Redesign and detailed plans shall be submitted to the Owner/Engineer for approval. No additional compensation will be provided for changes in the work, either his/her own or others, caused by such redesign.

I. Raceways and conductors for lighting, switches, receptacles and other miscellaneous low voltage power and signal systems as specified are not shown on the Drawings. Raceways and conductors shall be provided as required for a complete and operating system. Refer to riser diagrams for signal system wiring. Homeruns, as shown on the Drawings, are to assist the Contractor in identifying raceways to be run exposed and raceways to be run concealed. Raceways installed exposed shall be near the ceiling or along walls of the areas through which they pass and shall be routed to avoid conflicts with HVAC ducts, cranes hoists, monorails, equipment hatches, doors, windows, etc. Raceways installed concealed shall be run in the center of concrete floor slabs, above suspended ceilings, or in partitions as required. In some cases, existing concealed raceways may be reused and in other cases concealed raceways both single runs and duct banks shall be provided as indicated or where found to be necessary to complete the installation as specified.

J. The Contractor shall run all conduit and wire to RTU and/or PLC termination cabinets, where designated on the Drawings. The conduit and wire as shown on the interface drawings may not necessarily be shown on the floor plan.

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K. Install conductors carrying low voltage signals (typically twisted shielded pair cables) in raceways totally separate from all other raceways containing power or 120-volt control conductors. Fiber optic cables shall also be routed in raceways totally separate from all other raceways caring any other metallic conductors.

L. Raceways and conductors for thermostats controlling HVAC unit heaters, exhaust fans and similar equipment are not shown on the Drawings. Provide raceways and conductors between the thermostats, the HVAC equipment and the motor starters for a complete and operating system. All raceways and power conductors shall be in accordance with Division 16. Raceways shall be installed concealed in all finished space and may be installed concealed or exposed in process spaces. Refer to the HVAC drawings for the locations of the thermostats and controls.

3.2 EQUIPMENT PADS AND SUPPORTS

A. Electrical equipment pads and supports, of concrete or steel including structural reinforcing and lighting pole foundations, are shown on the Structural Drawings.

B. No electrical equipment or raceways, shall be attached to or supported from, sheet metal walls.

3.3 SLEEVES AND FORMS FOR OPENINGS

A. Provide and place all sleeves for conduits penetrating floors, walls, partitions, etc. Locate all necessary slots for electrical work and form before concrete is poured.

B. Exact locations are required for stubbing-up and terminating concealed conduit. Obtain shop drawings and templates from equipment vendors or other subcontractors and locate the concealed conduit before the floor slab is poured.

C. Where setting drawings are not available in time to avoid delay in scheduled floor slab pours, the Owner/Engineer may allow the installations of such conduit to be exposed. Requests for this deviation must be submitted in writing. No additional compensation for such change will be allowed.

D. Seal all openings, sleeves, penetration and slots as specified in Section 16110.

3.4 CUTTING AND PATCHING

A. Coordinate with Divisions 2 and 3 for cutting and patching.

B. Core drill holes in concrete floors and walls as required. The Contractor shall obtain written permission from the Owner/Engineer before core drilling any holes larger than 2 inches.

C. Install work at such time as to require the minimum amount of cutting and patching.

D. Do not cut joists, beams, girders, columns or any other structural members.

E. Cut opening only large enough to allow easy installation of the conduit.

F. Patching shall be of the same kind and quality of material as was removed.

G. The completed patching work shall restore the surface to its original appearance or better.

H. Patching of waterproofed surfaces shall render the area of the patching completely waterproofed.

I. Remove rubble and excess patching materials from the premises.

J. When existing conduits are cut at the floor line of wall line, they shall be filled with grout of suitable patching material.

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3.5 INSTALLATION

A. Any work not installed according to the Drawings and this Section shall be subject to change as directed by the Owner/Engineer. No extra compensation will be allowed for making these changes.

B. All dimensions shall be field verified at the job site and coordinated with the work of all other trades.

C. Electrical equipment shall be protected at all times against mechanical injury or damage by water. Electrical equipment shall not be stored outdoors. Electrical equipment shall be stored in dry permanent shelters as required by each Specification Section. Do not install electrical equipment in its permanent location until structures are weather-tight. If any apparatus has been subject to possible injury by water, it shall be thoroughly dried out and tested as directed by the Owner/Engineer, or shall be replaced at no additional cost at the Owner/Engineer's discretion.

D. Equipment that has been damaged shall be replaced or repaired by the equipment manufacturer, at the Owner/Engineer's discretion.

E. Repaint any damage to the factory applied paint finish using touch-up paint furnished by the equipment manufacturer. If the metallic portion of the panel or section is damaged, the entire panel or section shall be replaced, at no additional cost to the Owner.

3.6 PHASE BALANCING

A. The Drawings do not attempt to balance the electrical loads across the phases. Circuits on motor control centers and panelboards shall be field connected to result in evenly balanced loads across all phases.

B. Field balancing of circuits shall not alter the conductor color coding requirements as specified in Section 16120.

3.7 MANUFACTURER’S SERVICE

A. Provide manufacturer's services for testing and start-up of the equipment as listed in each individual Specification Section. All settings, including those settings and arc flash labels required by the Power System Study, shall be made to the equipment and approved by the Owner/Engineer prior to energizing of the equipment.

B. Testing and startup shall not be combined with training. Testing and start-up time shall not be used for manufacturers warranty repairs.

3.8 TESTS AND SETTINGS

A. Test systems and equipment furnished under Division 16 and repair or replace all defective work. Make adjustments to the systems as specified and/or required.

B. Prior to energizing electrical equipment, make all tests as required by the individual specification Sections. Submit a sample test form or procedure. and submit the required test reports and data to the Owner/Engineer for approval at least two weeks prior to the startup of the tested equipment. Include names of all test personnel and initial each test.

C. Check motor nameplates for correct phase and voltage. Check bearings for proper lubrication.

D. Check wire and cable terminations for tightness.

E. Check rotation of motors prior to energization. Disconnect driven equipment if damage could occur due to wrong rotation. If the motor rotates in the wrong direction, the rotation shall be immediately corrected, or tagged and locked out until rotation is corrected.

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F. Verify all terminations at transformers, equipment, capacitor connections, panels, and enclosures by producing a 1 2 3 rotation on a phase sequenced motor when connected to "A", "B" and "C" phases.

G. Mechanical inspection, testing and setting of circuit breakers, disconnect switches, motor starters, control equipment, etc for proper operation.

H. Check interlocking, control and instrument wiring for each system and/or part of a system to prove that the system will function properly as indicated by schematic and wiring diagrams.

I. Check the ampere rating of thermal overloads for motors and submit a typed record to the Owner/Engineer of same, including MCC cubicle location and load designation, motor service factor, horsepower, full load current and starting code letter. If inconsistencies are found, new thermal elements shall be supplied and installed.

J. Verify motor power factor capacitor ratings.

K. Testing shall be scheduled and coordinated with the Owner/Engineer at least two weeks in advance. Provide qualified test personnel, instruments and test equipment.

L. Refer to the individual equipment sections for additional specific testing requirements.

M. Make adjustments to the systems and instruct the Owner's personnel in the proper operation of the systems.

3.9 TRAINING

A. The Contractor shall provide manufacturer’s training as specified in each individual section of the Specifications.

END OF SECTION

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EXCAVATION, TRENCHING, BACKFILLING AND COMPACTION FOR ELECTRICAL APPLICATIONS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16022 EXCAVATION, TRENCHING, BACKFILLING AND COMPACTION FOR ELECTRICAL APPLICATIONS.DOCX

SECTION 16022 EXCAVATION, TRENCHING, BACKFILLING AND COMPACTION FOR ELECTRICAL APPLICATIONS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required to perform all excavation, trenching for electrical duct work and appurtenances, including drainage, bedding, filling, backfilling, disposal of surplus material, and restoration of trench surfaces and easements.

1.2 RELATED WORK

A. Section 16000 Electrical General Provisions

B. Section 16033 Cast-in-Place Concrete for Electrical Applications.

C. Section 16110 Raceways, Boxes and Fittings

D. Section 16600 Underground System

E. Section 16120 Wire and Cables (1000 Volt Maximum).


A. All excavation, trenching, and related sheeting, bracing, etc., as shown on the Drawings and listed in these Specifications, shall comply with the following standards (unless otherwise noted): 1. Occupational Safety and Health Administration (OSHA)

a. Excavation safety standards (29 CFR Part 1926.650 Subpart P) - Excavation. 2. American Society for Testing and Materials (ASTM)

a. ASTM D 698a – Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600kN-m/m3)).


PART 3 - EXECUTION

3.1 TRENCH EXCAVATION

A. The excavation shall extend to the width and depth as shown on the Drawings, or as specified, and shall provide suitable room for installing manholes, handholes, ducts and appurtenances.

B. Furnish and place all sheeting, bracing and supports.

C. Excavation shall include material of every description and of whatever substance encountered, regardless of the methods or equipment required to remove the material. Pavement shall be cut with a saw, wheel or pneumatic chisel along straight lines before excavating.

D. The Contractor shall strip and stockpile topsoil from grassed areas crossed by trenches. At the Contractor’s option, topsoil may be otherwise disposed of and replaced, when required, with approved topsoil of equal quality.

E. While excavating and backfilling is in progress, traffic shall be maintained, and all utilities and other property protected, as provided for in the Contract Documents.

F. Materials shall be excavated to the depth indicated on the Drawings and in widths sufficient for installing manholes and laying the ducts. Coordinate the trench width the Details shown on the Drawings. The bottom of the excavations shall be firm and dry in all respects acceptable to the

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Owner/Engineer. Trench width shall be a practical minimum, but not less than 6 inches greater than the total duct section arrangement, including reinforcing steel.

G. Excavation and dewatering shall be accomplished by methods which preserve the undisturbed state of subgrade soils. The trench may be excavated by machinery to, or just below, the designated subgrade, provided that material remaining in the bottom of the trench is no more than slightly disturbed. Subgrade soils which become soft, loose or otherwise unsatisfactory as a result of inadequate excavation, dewatering or other construction methods, shall be removed and replaced by gravel fill, of aggregate as specified in Section 16033, as required by the Owner/Engineer at the Contractor’s expense.

3.2 EXCAVATION BELOW GRADE AND REFILL

A. Regardless of the nature of unstable material encountered, or the groundwater conditions, trench and excavation drainage shall be complete and effective.

B. If deemed necessary by the Owner/Engineer, or as shown on the Drawings, the Contractor shall be required to deposit pea gravel for duct bedding or gravel refill for excavation below grade, directly on the bottom of the trench immediately after excavation has reached the proper depth and before the bottom of the trench has become softened or disturbed by any cause whatsoever. All excavation shall be made in open trenches. Gravel used for this purpose, shall be aggregate as specified in Section 16033, with a maximum coarse aggregate size of ¾ inch.

3.3 BACKFILLING

A. Remove from the excavation all materials which the Owner/Engineer may deem unsuitable for backfilling.

B. Backfilling shall not commence until, not less than 48 hrs after placing of any concrete embedment, have lapsed.

C. Where the duct banks are laid in the yard, the remainder of the trench, after concrete encasement, shall be filled with common fill material, void of rock or other non-porous material, in layers not to exceed 8-in in loose measure and compacted to 90% standard Proctor density at optimum moisture content of +/- 4%. The backfill shall be mounded 6-in above the existing grade or as directed by the Owner/Engineer. Where a grass, loam or gravel surface exists prior to excavations in the yard, it shall be removed, conserved and replaced to the full original depth as part of the work under the duct items. In some areas it may be necessary to remove excess material during the cleanup process, so that the ground may be restored to its original level and condition.

D. Where the duct banks are laid in paved areas or designated future paved areas, existing or designated future structures, or other existing or future utilities, the remainder of the trench above the encasement, shall be backfilled with select common fill or select fill material in layers not to exceed 8-inches loose measure and compacted at optimum moisture content (± 3%) to 95 percent standard Proctor density. The top 18-inches below subgrade level shall be compacted at optimum moisture content (+/- 3%) to 100 percent of standard Proctor density.

E. Compaction shall be by use of hand or pneumatic tamping with tools weighing at least 20 lbs. The material being spread and compacted shall be placed in layers not over 8-in. thick. If necessary, sprinkling shall be employed in conjunction with rolling or ramming.

F. Bituminous paving shall not be placed in backfill.

G. Water jetting will not be accepted as a means of consolidating or compacting backfill.

H. All road surfaces shall be broomed and hose-cleaned immediately after backfilling. Dust control measures shall be employed at all times.

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3.4 RESTORING TRENCH AND ADJACENT SURFACES

A. In paved areas, the edge of the existing pavement to be removed shall be cut along straight lines, and the pavement replaced with the same type and quality of the existing paving.

B. In locations where the duct bank passes through grassed areas, the Contractor shall, at his own expense, remove and replace the sod, or shall loam and reseed the surface to match the surrounding area.

END OF SECTION

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CAST-IN-PLACE CONCRETE FOR ELECTRICAL APPLICATIONS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16033 CAST-IN-PLACE CONCRETE FOR ELECTRICAL APPLICATIONS.DOCX

SECTION 16033 CAST-IN-PLACE CONCRETE FOR ELECTRICAL APPLICATIONS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, tools, equipment and related items required to perform the cast-in-place concrete work.

1.2 RELATED WORK

A. Section 16000 Electrical – General Provisions

B. Section 16022 Excavation, Trenching, Backfilling and Compaction for Electrical Applications.

C. Section 16110 Raceways, Boxes and Fittings.

D. Section 16600 Underground System.

E. Process Equipment Division 11 Specifications

F. Instrumentation Equipment Division 17 Specifications

G. Mechanical Equipment Division 15 Specifications

H. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

I. Other Divisions 1. The Contractor shall be responsible for examining all Sections of the Specifications and

Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submit to the Owner/Engineer, in accordance with Division 1 and Section 16000, product data for the following: 1. Submit test data for the proposed concrete design mix(es). 2. Submit manufacturer's technical literature, including application procedures, for the

following products: a. Admixtures. b. Form-coating materials. c. Concrete finishing and coating products. d. Curing materials. e. Any products proposed for use by the Contractor and not specified herein. The

Owner/Engineer reserves the right to reject any proposed products. 3. Hot weather and cold weather concreting plans as required by the project conditions.

Specifically note what constitutes hot or cold weather conditions.

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B. Certificates 1. Reinforcing Steel. Submit the manufacturer's certificates providing the properties of the

reinforcing steel proposed for use. 2. Submit mill certificates for all bulk cement.

C. Submit manufacturer's technical literature, including application procedures, for the following products: 1. Air entraining agents. 2. Admixtures. 3. Joint sealants. 4. Form-coating materials. 5. Concrete finishing and coating products. 6. Curing materials. 7. Any products proposed for use by the Contractor and not specified herein. The

Owner/Engineer reserves the right to reject any proposed products.

D. It is the Contractor's responsibility to provide all information required by the Owner/Engineer to evaluate and approve an alternate to any product listed as a standard of quality in this specification. The Owner/Engineer reserves the right to reject any proposed alternates.

E. Miscellaneous Submittals 1. Protective coatings procedures, including written warranties as specified herein. 2. Hot weather and cold weather concreting plans as required by the project conditions.

Specifically note what constitutes hot or cold weather conditions.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. American Concrete Institute (ACI)

a. ACI 301 Specifications for Concrete b. ACI 304R Guide to Measuring, Mixing, Transporting and Placing Concrete c. ACI 305R Hot Weather Concreting d. ACI 306R Cold Weather Concreting e. ACI 308 Standard Practice for Curing Concrete f. ACI 309R Guide to Consolidation of Concrete g. ACI 315 Detailing Manual: Details and Detailing of Concrete Reinforcement. h. ACI 318 Building Code Requirements for Reinforced Concrete i. ACI 347 Guide to Formwork for Concrete

2. American Society for Testing and Materials (ASTM) a. ASTM A185 Specification for Welded Steel Wire Fabric for Concrete

Reinforcement b. ASTM A615 Specification for Deformed and Plain Billet-Steel Bars for Concrete

Reinforcement c. ASTM C31 Method of Making and Curing Concrete Test Specimens in the Field d. ASTM C33 Specification for Concrete Aggregates e. ASTM C39 Test Method for Compressive Strength of Cylindrical Concrete

Specimens f. ASTM C94 Specification for Ready-Mixed Concrete g. ASTM C150 Specification for Portland Cement h. ASTM C171 Specification for Sheet Materials for Curing Concrete i. ASTM C172 Standard Practice for Sampling Freshly Mixed Concrete j. ASTM C260 Specification for Air-Entraining Admixtures for Concrete k. ASTM C309 Specification for Liquid Membrane-Forming Compounds for Curing

Concrete

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l. ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete.

3. Concrete Reinforcing Steel Institute (CRSI) Manual of Standard Practices.


A. The manufacturer of these materials shall have produced similar materials and equipment for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

1.6 DELIVERY STORAGE AND HANDLING

A. Materials shall be handled and stored in accordance with manufacturer's instructions.

B. Protect materials from exposure to the elements and keep thoroughly clean and dry until installation.

1.7 WARRANTY

A. The Contractor shall warrant the installation to be free from defects in material and workmanship for 1 year from date of final acceptance of the project. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the installation to new condition. Any warranty work requiring shipping or transporting of the equipment or materials shall be performed by the Contractor at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MATERIALS

A. All concrete shall be normal weight concrete weighing not more than 145 pcf with compressive strength a minimum of 3000 psi at 28 days, unless specified otherwise.

B. Cement 1. Cement shall be Portland cement conforming to ASTM C150, Types IA or IIA.

a. Type/ASTM No. Description 1) IA/C150 Standard Portland cement. 2) IIA/C150 Provides moderate sulfate resistance or moderate heat of

hydration. 2. Only one type and brand, selected from one of the above two, shall be used on this

project. Mixing of types will not be permitted.

C. Fly ash 1. Conform to ASTM C618, Class F, unless specified otherwise. 2. Fly ash shall be produced from a single known and consistent source. 3. The amount of fly ash used shall not exceed 25 percent by volume of the specified

cement volume (cement is specified by weight, which can be converted to an equivalent volume).

D. Aggregates 1. All aggregates shall be of the crushed type. River rock is not acceptable, 2. Fine aggregates shall conform to ASTM C33. 3. Coarse aggregates shall conform to ASTM C33, including the following size limitations:

a. ≤ 1/5 the narrowest dimension between sides of forms. b. ≤ 1/3 the depth of slabs. c. ≤ 3/4 the minimum clear spacing between reinforcing. d. ≤ 1/2 the minimum clear spacing between electrical ducts.

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4. Use coarse aggregate from only one source and fine aggregate from only one source for exposed concrete in a single structure.

5. Maximum coarse aggregate size shall be 3/4-inch.

E. Mixing Water shall be chloride free and potable.

F. Admixtures

1. Air entraining shall conform to ASTM C260.

G. Chlorides are not permitted in any form.

H. Reinforcing Steel 1. All reinforcing steel shall be epoxy-coated, sized as shown on the Drawings, and shall

conform to ASTM A 775, Grade 60, U.S. manufactured. 2. Clearly mark all bars with waterproof tags showing the number of bars, size, mark, length

and yield strength. 3. Tie wire shall be 18-gage annealed steel.

I. Welded Wire Fabric 1. Welded wire fabric shall conform to ASTM A185. 2. Welded wire fabric shall be of the wire size, spacing and type as shown on the Drawings. 3. Furnish in flat sheets only. Rolled sheets are not acceptable.

J. Bar Supports 1. Bar supports and accessories shall be of the sizes required to provide the concrete cover

specified. Where concrete surfaces are exposed to the weather, provide plastic accessories only. Use of galvanized or plastic-tipped metal is not permitted in these locations.

2. Precast concrete bar supports shall use the same class of concrete as specified for the structure. The height of the block shall be the height required to provide the cover specified for the reinforcing. The block shall contain wires for securing the block to the reinforcement.

K. Form work 1. Design and details of form work shall conform to ACI 347. 2. Use smooth forms on all concrete surfaces exposed to view or water. Rough forms may

be used on all concrete surfaces not exposed to view or water. Form material shall have sufficient strength and thickness to withstand the hydraulic pressure of newly placed concrete without deformation. a. Smooth Forms

1) Material shall be one of the following: a) Steel. b) Smooth-dressed wood. c) Plastic-faced plywood. d) Fiberglass e) Other material approved by the Owner/Engineer.

2) Provide continuous, straight smooth surfaces. Form material shall be free of raised grain, torn surfaces, worn edges, patches, dents, or other defects.

b. Rough forms shall be constructed of dressed or undressed lumber or plywood free of knots, splits, or other defects, or other material approved by the Owner/Engineer.

c. Provide chamfer strips at all edges of concrete exposed to view. Size of chamfer shall be 3/4 inch unless shown otherwise on the drawings.

L. Form Ties shall be as follows: 1. No metal or any other material shall be left within 1-1/2 inches of the concrete surface. 2. The form tie assembly shall provide cone-shaped depressions 1 inch diameter at the

surface and 1-1/2 inches deep to allow for patching of the tie holes.

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3. Tie rods to remain in place shall provide tight fitting washers at midpoint. Washers are not required for multi-rod ties.

4. Tie rods to be removed shall be tapered at the portion passing through the concrete, the large end of the taper on the liquid side.

M. Form Coating 1. Conform to ACI 347. 2. Form coating must not bond with, stain, or adversely affect concrete surfaces. 3. Form coating must not impair subsequent treatment of concrete surfaces, including

bonding agents, curing compounds, and waterproofing. 4. Form coating must be non-toxic or become non-toxic within 30 days.

N. Curing Materials 1. Membrane curing compounds shall conform to ASTM C309 as follows:

a. Solids: 18%. b. Unit moisture loss: < 0.039 gm/cm2 maximum at 72 hours. c. Rate of application: per the manufacturer or between 150 to 200 ft2/gal.

2. Polyethylene film for curing concrete shall conform to ASTM C171.

O. Miscellaneous Associated Materials 1. Use of all materials in this Section shall be in strict conformance with the respective

manufacturers' recommendations. Unacceptable workmanship as a result of the Contractor not adhering to the manufacturers' recommendations will be repaired or replaced at the Contractor's sole expense.

2. Protective Coatings a. All protective coatings work shall be provided by a coating applicator approved by

the coating manufacturer and the Owner/Engineer. The coating applicator shall obtain written procedures from the coatings manufacturer on application of the protective coatings under the project conditions, including surface preparation. All protective coatings work shall be in strict conformance with these written procedures.

b. Coordinate all protective coatings work so as not to delay construction.

2.2 PROPORTIONING OF CONCRETE

A. Select proportions of ingredients to produce a concrete having proper workability, durability, strength, and appearance. Proportion ingredients to produce a mixture that will work readily into corners and angles of forms and around reinforcement by methods of placing and consolidation employed on the project. Concrete mix shall not allow materials to segregate or allow excess free water to collect on the surface.

B. Minimum cementitious content shall be 564 lbs./cu yd.

C. The maximum allowable water/cement or water/cement-pozzolan ratio shall not exceed 0.4513. Include free water in the aggregate in all water/cement or water/cement-pozzolan ratio computations. Slump shall be approximately as follows:

Condition Slump (In.) 1. Underground ducts or raceways 4 - 6 2. All other applications 1- 4

D. Proportion admixtures according to the manufacturer's recommendations.

E. Minimum air content shall be as follows:

Coarse Aggregate Size Air Content 1. ¾” 6 +/- 1

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2.3 MIXING NORMAL WEIGHT CONCRETE

A. Mix and transport ready-mixed concrete according to ASTM C94 and ACI 304R. In addition to normal batch plant procedures as outlined in ASTM C94, provisions must be made at the batch plant for the following items: 1. Provide a moisture meter to assure the amount of free water in fine aggregates is within

0.3 percent. Compensate for varying moisture contents of fine aggregates and change batch weights of materials, if necessary, before batching.

2. Provide adequate facilities for accurate measurement and control of each material used in each batch of concrete. The accuracy of weighing equipment must conform to applicable requirements of ASTM for such equipment. Computerized plants which automatically correct for weigh-out variations must do so within the batch being loaded. Correction only for succeeding batches is not acceptable.

3. Ticket information for each truck of delivered concrete must include the following information: a. Truck number. b. Time truck left batch plant. c. Time truck arrived at construction site. d. Time concrete discharge started. e. Time concrete discharge completed. f. Weights for cement and aggregates as batched. g. The difference between aggregates and cement as batched and as specified. h. Concrete batch number. i. Total amount of water. j. Types and amounts of admixtures. k. Discharge temperature.

4. Deliver recorded ticket copies with concrete. Contractor must provide one original copy for each truckload to both the Owner/Engineer's testing agency and the Owner/Engineer at the end of each day. Maintain a copy of tickets for each day as a part of the job records.

B. Transit Mix Truck Requirements 1. Clean each truck drum before the truck proceeds to the batching plant. 2. Keep the water tank valve locked at all times of the truck that is in use. Any addition of

water must be as directed by the Owner/Engineer. 3. Equip each truck with a continuous, non-reversible, revolution counter showing the

number of revolutions at mixing speeds.

C. Admixtures 1. Charge admixtures into the mixer as a solution using an automatic dispenser or similar

metering device. Measure admixture to an accuracy within ±2 percent. Do not use admixtures in powdered form except for the red dye.

2. Two or more admixtures may be used in the same concrete, provided that the admixtures in combination retain full efficiency and have no deleterious effect on the concrete or on the properties of each other. Inject the admixtures separately during the batching sequence.

3. Where concrete is to be used to encase underground conduits in a duct bank configuration, the concrete shall be dyed red, with the die placed in the truck. Sprinkling the dye on top of the concrete after placement is strictly prohibited. Install red dye of 40 lbs per 10 cy. of concrete, to be installed in the truck at the concrete plant, before delivery.

2.4 FABRICATION OF CONCRETE REINFORCEMENT

A. Fabricate bars to the shapes shown on the Drawings by cold bending. Bends shall conform to the minimum bend diameters specified in ACI 318. Do not straighten or re-bend bars.

B. Locate splices as shown on the drawings. Where it is necessary to splice reinforcement at locations other than as shown on the drawings, the splices shall be approved by the

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Owner/Engineer. Stagger splices in adjacent bars. Length of lap splices shall be in accordance with ACI 318, unless detailed otherwise on the drawings.

C. Fabricating and placing tolerances shall be in accordance with ACI 318, ACI 301, and the CRSI Manual of Standard Practice.

2.5 CONCRETE CURING MATERIALS

A. Concrete curing materials shall be compatible with all specified coatings.

PART 3 - EXECUTION

3.1 REINFORCEMENT PLACEMENT

A. Place and hold reinforcement in position so that the concrete cover, as measured from the surface of the bar to the form surface, is as follows, unless noted otherwise on the drawings:

Location Cover (in.)

1. Concrete cast against 3 and permanently exposed to earth 2. All other concrete 3

B. Support reinforcing bars to prevent displacement by construction loads or concrete placement beyond the specified tolerances.

C. Do not bend reinforcement after being embedded in hardened concrete, unless approved by the Owner/Engineer.

D. Bars may be moved as necessary to avoid interference with other reinforcing steel, conduits, or embedded items. If bars are moved more than 1 bar diameter, or enough to exceed the specified tolerances, the resulting arrangement of bars shall be subject to approval by the Owner/Engineer.

E. Splices 1. Do not splice bars, except at locations shown on the drawings or the reviewed shop

drawings, without approval of the Owner/Engineer. 2. Tie lap splices securely with wire to prevent displacement of splices during placement of

concrete.

F. Place reinforcing continuous through construction joints, unless otherwise shown on the design drawings.

G. Install welded wire fabric in the largest sections practical. Lap adjoining pieces at least one full mesh plus 2 inches or 12 inches, whichever is larger. Lace splices with wire. Do not make end laps midway between supporting beams, or directly over beams of continuous structures. Offset end laps in adjacent widths to prevent continuous laps.

H. Reinforcing bars field cut on the job shall be cut by shearing or sawing. Field cutting with a torch is not acceptable.

I. Welding of reinforcing bars is prohibited.

3.2 FORM CONSTRUCTION AND HANDLING

A. Form joints shall be mortar tight. Grout leakage at joints is unacceptable.

B. Where necessary to maintain the specified tolerances, camber formwork to compensate for anticipated deflections in the formwork due to the weight and pressure of the fresh concrete and construction loads.

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C. Form panels shall be constructed in the largest sizes allowable by handling and load bearing requirements.

D. Plywood and other wood surfaces shall be sealed against absorption of moisture from the concrete.

E. Clean form surfaces before use and re-use.

F. Assemble forms so that they may be readily removed without damage to concrete surfaces.

G. Drill forms to suit ties used and to prevent leakage of concrete mortar around the holes. Do not damage forms by driving ties through improperly prepared holes.

H. Provide sharp, clean corners at intersecting planes, without visible edges or offsets. Back joints with extra studs or girts to maintain true, square intersections.

I. Removal of forms shall conform to ACI 347.

J. When repair of vertical surface defects or finishing is required before concrete is cured, remove formwork as soon as concrete has hardened sufficiently to resist damage from removal operations.

K. Remove form ties as soon as possible after formwork removal, not to exceed 48 hours.

3.3 INSPECTION

A. Before concrete placement, all reinforcement shall be free of mud, oil, coating or other materials that may adversely affect or reduce bond. Reinforcing with rust or mill scale not removable by wire brush, will be accepted provided the dimensions, weights and height of deformations of a cleaned sample are not less than required by the applicable ASTM specifications. All reinforcing steel shall be securely tied and supported to prevent displacement by construction loads or concrete placement beyond the tolerances specified in item 2.04. Forms shall be clean and free from loose material or debris.

B. Notify the Engineer twenty-four (24) hours prior to the start of concrete placement to allow for inspection of the reinforcing steel placement. Costs due to delays resulting from corrective work will be borne by the Contractor at no additional expense to the Owner/Engineer.

C. Physical properties of reinforcing steel are subject to testing by an independent laboratory for compliance with ASTM A615. Furnish samples required for such testing when requested by the Owner/Engineer.

D. Any costs due to embedded items not being placed prior to concrete placement shall be borne by the Contractor at no additional expense to the Owner/Engineer.

3.4 CONSTRUCTION JOINTS

A. Joints shall be located where shown on the drawings. The addition or deletion of joints is permitted only upon written approval by the Owner/Engineer.

B. Clean surface of the concrete at all joints and remove laitance.

3.5 CONVEYING

A. Handle concrete from mixer to placement as quickly as practical while providing concrete of required quality. Use methods which prevent loss of ingredients and segregation.

3.6 PLACEMENT OF CONCRETE

A. Placement of concrete shall conform to ACI 304R.

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B. In the event of plant or equipment breakdowns, backup concrete placing equipment shall be available within 30 minutes. An alternate concrete source that can provide concrete in accordance with these specifications and the approved mix design shall be considered.

C. Concrete shall be placed in approximately 12 inches to 24 inches horizontal layers. Conform to ACI 309R.

D. Concrete shall not be dropped freely more than 4 feet or through a cage of reinforcing steel.

E. Bottom-dump buckets are acceptable as long as care is take to avoid segregation caused by jarring or bumping the bucket.

F. Chutes 1. Chutes shall be metal or wood with metal lining. Aluminum is unacceptable. 2. Slope shall be between one vertical to two horizontal and one vertical to three horizontal. 3. A baffle shall be provided at the end of each chute unless a drop chute, tremie, or

elephant truck is used.

G. Drop Chutes, Elephant Trunks, and Tremies 1. Drop chutes, elephant trunks, and/or tremies shall be used in walls and columns. 2. Drop chutes, elephant trunks, and tremies shall be moved at short intervals during the

pour. Vibrators shall not be used in lieu of proper movement of this equipment. 3. Tremies shall be used for underwater pours and to avoid segregation.

H. Pumping 1. Pumping equipment shall be compatible with the slump and aggregate size specified. 2. Aluminum pump lines are unacceptable. 3. Loss of slump from the pump hopper to the delivery point shall not exceed 1-1/2 inches.

I. Conveying 1. Conveying equipment shall be designed to place concrete without segregation. 2. Conveying equipment shall deliver concrete continuously over the placement area

without delays for equipment relocation.

J. Portholes may be placed in wall or column forms in order to limit the free fall of concrete to less than 4 feet. In walls, porthole spacing shall not exceed 6 feet to 8 feet.

K. Placing in Forms 1. At least 48 hours shall elapse before placement of an adjacent section of wall. 2. Vibration of successive layers of poured concrete is required. The vibrator shall not

penetrate the underlying layer by more than 2 feet. 3. The use of vibrators to move concrete horizontally within the forms is unacceptable. 4. Vibrators

a. Conform to ACI 309R. b. Vibrators shall be high frequency with a minimum frequency of 8,000 rpm. c. Continue vibration until the escape of large bubbles at the surface has ceased and

before segregation occurs. d. Vibrators or sharp pointed concrete placing tools shall not be used on concrete

placed in underground electrical duct trenches. 5. If forms become displaced in any way during placing of concrete, immediately stop the

operation and do not resume placing until forms have been re-braced and brought back to required lines and levels.

6. Concrete placing procedures and equipment shall not dislodge reinforcing steel or other embedded items in concrete structure.

L. Weather Conditions 1. Do not place concrete during rain, sleet, snow or freezing weather. 2. Do not permit rainwater to increase mixing water or to damage the surface finish. If

rainfall occurs after placing operations begin, provide adequate covering to protect the work.

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3. Hot Weather a. Conform to ACI 305R. b. The hot weather concreting plan shall be submitted to the Engineer for review. c. The maximum permissable temperature of concrete during placement is 90

degrees F. 4. Cold Weather

a. Conform to ACI 306R. b. When the temperature is 40 degrees F and rising, concrete may be placed as long

as the water and/or aggregate is heated so that the concrete temperature is at least 55 degrees F at the time of pour. The placed concrete shall be maintained at 50 degrees F minimum for 7 days minimum.

c. The cold weather concreting plan shall be submitted to the Owner/Engineer for review.

d. Vibrators or sharp pointed concrete placing tools shall not be used on concrete placed in underground electrical duct trenches.

3.7 CONCRETE

A. Delivery Schedule. Mix concrete only in quantities for immediate use. Discard concrete which has set. Re-tempering of set concrete is not permitted. Completely discharge concrete at the site within 90 minutes after adding cement to aggregate. In hot weather, the Contractor shall carefully monitor concrete quality and adjust delivery schedule and batching operations as required.

B. Indiscriminate addition of water to increase slump is prohibited. Do not exceed either the maximum specified water/cement or water/cement-pozzolan ratio or maximum slump. Any addition of water above the maximum water/cement or water/cement-pozzolan ratio is cause for rejection. If mixes continually arrive on the site with slump of 2 inches or less at the maximum allowable water/cement or water/cement-pozzolan ratio, revise concrete mix. The revised concrete mix shall be submitted to the Owner//Engineer for approval.

C. If concrete arrives with cement balls, balls shall be removed. Excessive balling is grounds for rejection of the truck. Trucks carrying balled concrete shall have their numbers taken. If the same truck arrives at the site carrying balled concrete three times, it will be rejected and not allowed to return to the site until it is opened up for inspection, cleanliness and damage noted, repairs made, and a final inspection for approval is made by the Owner/Engineer.

D. Concrete for placement in encasing underground duct banks shall be dyed red with the dye placed in the mixture in the truck at the concrete plant. Sprinkling dye on top of the concrete after placement encasing the duct bank is strictly prohibited.

3.8 CURING AND PROTECTION

A. Curing shall conform to ACI 308.

B. Protect freshly deposited concrete from premature drying, excessively hot or cold temperatures, and excessive moisture loss for a period of time necessary for the hydration of the cement and proper hardening of the concrete.

C. Curing shall begin immediately following the initial set of concrete or surface finishing has been completed, as soon as surface marring will not occur as a result of curing operations.

D. Wall forms may be left in place as a means of curing unless the weather is hot and dry. Consult with the Owner/Engineer concerning weather conditions acceptable for leaving wall forms in place. Cure concrete immediately after the removal of forms in hot and dry weather, in accordance with the requirements and procedures specified herein.

E. During the curing period, protect concrete from damaging mechanical disturbances, such as load stresses, heavy shock, and excessive vibration. Protect finished concrete surfaces from

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damage caused by construction equipment, materials, or methods, and by rain or running water.

F. Curing Requirements and Procedures

3.9 CONCRETE FINISHING

A. Repairing Surface Defects 1. Repair surface defects immediately after the removal of forms. 2. Remove honeycombed and other defective concrete down to sound concrete and repair. 3. Patch tie holes immediately after removal of forms. Fill solid with patching material as

submitted to and approved by the Owner/Engineer. 4. The Contractor shall submit patching material(s) and method(s) of application to the

Owner/Engineer for approval.

B. Finishing of Formed Surfaces 1. Rough form finish shall be in accordance with ACI 301, Section 10.2.1. 2. Smooth form finish shall be in accordance with ACI 301, Section 10.2.2. 3. Smooth rubbed finish shall be in accordance with ACI 301, Section 10.3.1. A smooth

rubbed finish requires an initial smooth form finish as required above. 4. Grout cleaned finish shall be in accordance with ACI 301, Section 10.3.2. A grout cleaned

finish requires an initial smooth form finish as required above. 5. Tops of walls and similar unformed surfaces occurring adjacent to formed surfaces shall

be struck smooth after concrete is placed. Float unformed surfaces to a texture consistent with that of the formed surfaces. Final treatment on formed surfaces shall continue uniformly across the unformed surfaces.

C. Finishing Slabs and Similar Flat Surfaces 1. Use strike-off templates or approved compacting-type screeds riding on screed strips or

edge forms to bring concrete surface to the proper contour. 2. Thoroughly consolidate concrete in slabs. 3. Tolerances shall be checked by placing a straightedge of specified length anywhere on

the slab. The gap between slab and straightedge must not exceed the tolerances listed below.

Class Straightedge Length (ft.) Tolerance (in.) All 10 1/8

4. Floated Finish a. All equipment pads and slabs, installed indoors, shall have a floated finish, smooth

and level. b. Replace any floated finishes, cut or damaged, during the Project. c. After concrete has been placed, struck off, consolidated and leveled, do not work

further until ready for floating. Begin floating when water sheen has disappeared, or when the mix has stiffened sufficiently to permit proper operation of a power driven float. Consolidate the surface with power driven floats. Use hand floating with wood or cork faced floats in locations inaccessible to a power driven machine and on small, isolated slabs.

d. Recheck tolerance of the surface after initial floating with a 10-foot straightedge applied at not less than two different angles. Cut down high spots and fill low spots to Class B tolerance. Immediately re-float slab to uniform, smooth, granular texture.

5. Troweled Finish a. Replace any troweled finishes, cut or damaged, during the Project. b. To obtain a troweled finish, a floated finish as specified above must be applied.

After power floating, use a power trowel to produce a smooth surface which is relatively free of defects but which may still contain some trowel marks. Do additional troweling by hand after the surface has hardened sufficiently. Do final

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troweling when a ringing sound is produced as the trowel is moved over the surface. Thoroughly consolidate the surface by hand troweling operations.

c. Produce a finished surface free of trowel marks, uniform in texture and appearance and conforming to Class A tolerance. On surfaces intended to support floor coverings, remove defects which might show through covering by grinding.

6. Broom Finished Concrete

a. All equipment pads and slabs, installed outdoors, shall have a broomed finish, smooth and level.

b. Replace any broom, belt or rake finished concrete, cut or damaged during the Project.

c. To obtain a broom, belt, or rake finish, immediately upon completing a floated finish, draw a broom or rake across the surface to give a coarse transverse scored texture.

D. Protective Coatings

E. Sealers

3.10 TESTING AND CONTROL FURNISHED BY THE CONTRACTOR

A. In addition to the initial mix design, the Contractor shall, at his expense, employ a commercial testing laboratory, acceptable to the Owner/Engineer, to prepare and test the design mix for each class of concrete for which the material source has been changed.

3.11 REPLACEMENT AND RETESTING OF DEFICIENT IN-PLACE CONCRETE

A. The strength of the concrete will be considered potentially deficient if the averages of two consecutive sets of strength test results fail to equal or exceed the specified strength or if any individual strength test result falls below the specified strength. Testing may be required as directed by the Owner/Engineer.

B. Concrete work not having the required strength, as determined by the Owner/Engineer, shall be replaced at the Contractor's expense.

C. The Contractor shall bear all costs incurred in providing the additional testing and/or analyses required as a result of deficient in-place concrete. All costs as a result of delays due to additional testing and/or analyses will be at the Contractor's expense, with no extension of contract length, regardless of the outcome of the testing.

3.12 ACCEPTANCE OF CONCRETE WORK

A. Formed surfaces resulting in a configuration of members smaller than permitted under the tolerances specified herein shall be considered deficient and repaired or replaced as directed by the Owner/Engineer.

B. Concrete members cast in the wrong location shall be rejected if the strength, appearance, or function of the structure is, in the Owner/Engineer's opinion, adversely affected or if misplaced members interfere with other construction. If rejected, remove members cast in the wrong location and repair or replace at the Contractor's expense as directed by the Owner/Engineer.

C. All work required under this Section shall be at the Contractor's expense, with no extension of contract length.

3.13 WATERTIGHTNESS OF CONCRETE STRUCTURES

A. All concrete structures, such as transformer insulation fluid containments designed to contain or convey fluid, shall be tested for water tightness by the Contractor by filling with water to levels approximating what will be attained during operation and testing as outlined in this

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Section. These tests shall be repeated until water tightness is assured. Unless approved by the Owner/Engineer, perform tests prior to backfilling below-grade structures.

B. The Contractor shall provide the water and all equipment required to fill and drain the structure for water tightness testing. The source of water and the means of filling and draining shall be submitted to the Owner/Engineer for approval.

C. The Contractor is responsible for all costs associated with the water tightness requirements specified herein and the repairs required as a result of water leakage.

D. The rate of filling shall be limited to minimize shock effect to new concrete construction. Rate of filling shall be submitted to the Owner/Engineer for approval.

E. Whenever raceways or any other item terminates in or extends through a concrete manhole or handhole the Contractor shall install the embedded item in the concrete such that the water tightness of the structure is not impaired. Unless otherwise noted, all raceways penetrating hydraulic structures shall have pipe sleeves.

END OF SECTION

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ELECTRICAL SUPPORT HARDWARE Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16045 ELECTRICAL SUPPORT HARDWARE.DOCX

SECTION 16045 ELECTRICAL SUPPORT HARDWARE

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish and install electrical support hardware, as shown on the Drawings and as specified herein.

B. Hardware shall include anchor systems, adhesive anchor systems, metal framing systems, and other electrical support systems, as shown on the Drawings and specified herein.

1.2 RELATED WORK

A. Division 16 Specifications

B. Process Equipment Division 11 Specifications

C. Instrumentation Equipment Division 17 Specifications

D. Mechanical Equipment Division 15 Specifications

E. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

F. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submit to the Owner/Engineer, in accordance with Division 1, the manufacturers' names and product designation or catalog numbers for the types of materials specified or shown on the Drawings. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

B. The submittal information, for anchor systems, shall contain manufacturer's specifications and technical data including; 1. Acceptable base material conditions (i.e. cracked, un-cracked concrete) 2. Acceptable drilling methods 3. Acceptable bore hole conditions (dry, water saturated, water filled, under water) 4. Manufacturer's installation instructions including bore hole cleaning procedures and

adhesive injection. 5. Cure and gel time tables 6. Temperature ranges (storage, installation and in-service).

C. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will

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be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NFPA 70 National Electrical Code (NEC) 2. NFPA 70E Standard For Electrical Safety in the Workplace 3. ASTM E 488-96 (2003); Standard Test Method for Strength of Anchors in Concrete and

Masonry Elements, ASTM International. 4. ASTM E 1512-93, Standard Test Methods for Testing Bond Performance of Adhesive-

Bonded Anchors, ASTM International 5. AC308; Acceptance Criteria for Post-Installed Anchors in Concrete Elements, Latest

revision. 6. SAE 316 Stainless Steel Grades

B. All equipment components and completed assemblies specified in this Section of the Specifications, having a UL standard, shall bear the appropriate label of Underwriters Laboratories.




A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner/Engineer upon delivery of the equipment, an approved copy of all such submittals. Delivery of incomplete constructed equipment, onsite factory work, or failed factory tests will not be permitted.


C. Adhesive Anchor Systems. 1. Deliver materials undamaged in Manufacturer's clearly labeled, unopened containers,

identified with brand, type, and ICC-ES Evaluation Report number. 2. Coordinate delivery of materials with scheduled installation date, minimizing storage time

at job-site. 3. Store materials under cover and protect from weather and damage in compliance with

Manufacturer's requirements, including temperature restrictions. 4. Comply with recommended procedures, precautions or remedies described in material

safety data sheets as applicable. 5. Do not use damaged or expired materials. 6. Storage restrictions (temperature range) and expiration date must be supplied with

product

D. Metal Framing Systems 1. Material shall be new and unused, with no signs of damage from handling.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of

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warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition.

PART 2 - PRODUCTS

2.1 ANCHORING SYSTEMS


acceptable: a. HILTI Kwik Bolt 3 b. Approved equal


B. Product Description 1. Torque controlled expansion anchor consisting of anchor body, expansion element

(wedges), washer and nut. Anchor shall be used for anchor sizes less than 3/8 inch. 2. All parts shall be manufactured of 316 stainless steel materials conforming to SAE 316. 3. UL 203 Rated.

2.2 ADHESIVE ANCHORING SYSTEMS


acceptable: a. HILTI HIT-RTZ with HIT-HY 200 MAX. b. Approved equal


B. Product Description 1. Anchor body with helical cone shaped thread on the embedded end and standard

threads on the exposed end, with washer and nut, inserted into Injection adhesive. Anchor shall be used for anchor sizes 3/8 inch and larger.

2. All parts shall be manufactured of 316 stainless steel materials conforming to SAE 316 standards.

2.3 U-CHANNEL SUPPORT SYSTEMS


acceptable: a. Tyco Unistrut b. Cooper B-Line c. Super-Strut d. No Approved equal


B. Product Description 1. Metal framing system for use in the mounting or support of electrical systems, panels

and enclosures, and including lighting fixture supports, trapeze hangers and conduit supports.

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2. Components shall consist of telescoping channels, slotted back-to-back channels, double wide channels, end clamps all-thread rod and conduit clamps.

3. Minimum sizes shall be 13/16” through 3-1/4” 4. Components shall be assembled by means of flat plate fittings, 90-degree angle fittings,

braces, clevis fittings, U-fittings, Z-fittings, Wing-fittings, Post Bases, channel nuts, washers, etc.

5. Field welding of components will not be permitted. 6. Unless otherwise specified or shown on the Drawings, all parts shall be manufactured of

316 stainless steel material conforming to SAE 316. 7. Framing systems for chlorine and ammonia rooms shall be manufactured of structural

fiberglass.

PART 3 - EXECUTION

3.1 GENERAL

A. The Contractor shall install all equipment strictly in accordance with the manufacturer's instructions and the Contract Drawings.

B. The location of all devices is shown, in general, on the Drawings and may be varied within reasonable limits so as to avoid any piping or other obstruction without extra cost, subject to the approval of the Owner. Coordinate the installation of the devices for piping and equipment clearance.

C. No electrical equipment or raceways, shall be attached to or supported from, sheet metal walls.


E. Where channel assemblies support electrical enclosures mounted to an aluminum back plate, and the structure is free standing, not located against walls, hand rails or other existing structural supports, the vertical channels shall be reinforced to provide a structure which is steady when free standing. Provide double channels, or double wide channels back to back and if necessary add one or more additional vertical supports to provide a steady and sturdy structure. Under no circumstances will any angle braces be permitted. Where the structure is mounted close to another structure and only 12 inches or less clearance is present, then horizontal braces between the panel structure and the existing building structure or hand rail is acceptable but only with Engineering approval. If, upon inspection, the structure is not satisfactory to the Engineer, then the Contractor shall provide additional vertical supports with no increase in the Contract Price.




3.3 POST INSTALLED ANCHOR SYSTEMS

A. Prior to installation of the anchor systems, the hole shall be clean and dry in accordance with the manufacturer’s instructions.

3.4 CLEANING

A. Remove all rubbish and debris from inside and around the installation. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.

END OF SECTION

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ELECTRICAL DEMOLITION Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16060 ELECTRICAL DEMOLITION.DOCX

SECTION 16060 ELECTRICAL DEMOLITION

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish, install and test all equipment, wiring and appurtenances as may be required to perform the electrical demolition shown on the Drawings and as specified herein.

1.2 SCHEDULES

A. Schedule with the Owner/Engineer for required shutdowns to accommodate system demolition and installation of temporary facilities.

1.3 STANDARDS

A. Temporary wiring of systems to maintain operation of facilities while undergoing modifications and demolition shall be provided in accordance with: 1. American National Standards Institute / National Fire Protection Association

(ANSI/NFPA), No. 70 – National Electrical Code (NEC), Article No. 590 – Temporary Wiring.


A. Verify field measurements and circuiting arrangements are as shown on the Drawings.

B. Verify that abandoned wiring and equipment serve only abandoned facilities.

C. Demolition drawings are based on casual field observation and existing record documents. Discrepancies shall be reported to the Owner/Engineer before disturbing the existing installation.

D. By beginning demolition, the Contractor accepts the existing conditions and warrants that he will maintain service to equipment and items not scheduled or indicated for removal.

PART 2 - PRODUCTS


A. Materials and equipment for patching and extending work: As specified in individual Sections.

2.2 DESIGN AND CONSTRUCTION

A. If temporary electrical wiring and facilities are required, the Contractor shall provide such wiring and facilities to comply with the NEC.

PART 3 - EXECUTION

3.1 PREPARATION

A. Disconnect electrical systems in walls, floors and ceilings scheduled for removal.

B. Coordinate utility service outages if required with the Plant Staff if the source is inside the plant, or coordinate with the Plant Staff and the Utility Company if an outage from the Utility is required. The Contractor shall provide generation or other means as specified here in or otherwise required to provide continuous service to operating equipment.

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C. Provide temporary wiring and connections to maintain existing systems in service during construction. When work must be performed on energized equipment or circuits, use personnel experienced in such operations.

D. Existing Electrical Service: Maintain existing system in service until new system is complete and ready for service. Disable system only to make switchovers and connections. Obtain permission from the Owner/Engineer at least one week in advance, before partially or completely disabling system.

E. The Owner’s process operations shall continue without interruption throughout the project demolition and construction as required by the Owner and/or regulating bodies including but not limited to the EPA, and State or Local authorities having jurisdiction. 1. As required to meet the Owner’s process requirements, the Contractor shall provide on-

site generation with the capacity and voltage required by the Owner’s power system to prevent process interruptions unacceptable to the Owner. The contractor shall include all engine-generator fluids and fuel and rental expenses for the duration required by the work.

2. The Contractor is responsible to examine the Contract Documents and make any site visits necessary, including interviews with Owner’s Personnel to determine what process are required to remain in service prior to bidding. The contactor shall include all costs to keep the required process in operation including all materials, labor, expenses required by the electric Utility serving the project site and on-site generation. The determination of the requirements for continued process operations prior to bidding is the responsibility of the Contractor. No increase in Contract Time or Price will be allowed if this requirement is not met by the Contractor.

3. If the Contractor fails to provide adequate power to keep the process in operation which causes a regulatory body to levy fines against the Owner, the Contractor shall reimburse the Owner for such expenses. No increase in Contract Price will be allowed.

3.2 DEMOLITION AND EXTENSION OF EXISTING ELECTRICAL WORK

A. Remove, relocate and extend existing installations to accommodate new construction.

B. Remove abandoned wiring to source of supply.

C. Remove exposed abandoned conduit, including abandoned conduit above accessible ceiling finishes. Cut conduit flush with walls and floors, and patch surfaces.

D. Disconnect abandoned outlets and remove devices. Remove abandoned outlets if conduit serving them is abandoned and removed. Provide blank cover for abandoned outlets which are not removed.

E. Disconnect and remove abandoned panelboards and distribution equipment.

F. Disconnect and remove electrical devices and equipment that has been removed.

G. Repair adjacent construction and finishes damaged during demolition and extension work.

H. Maintain access to existing installations which remain active. Modify installation or provide access to panels as appropriate.

I. Where the demolition or revision of any portion of a raceway or box in the raceway system, in an area, causes the raceway system of the area to no longer comply with the classification or specification requirements of the area, the Contractor shall provide and install such boxes, fittings, etc. as may be necessary to return the raceway system to compliance with Specifications.

J. Extend existing installations using materials and methods as specified for new work.

K. Carry out the work in an orderly and careful manner. Hold noise, dust, and vibration to a minimum and conduct the Work so as to avoid any damage to the surroundings. Remove all

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items and parts as shown and noted on the Drawings and as otherwise may be required to be removed to carry out the Work.

L. Salvaged Equipment and Materials 1. The Owner shall have the right to retain any or all electrical and instrumentation

equipment shown or specified to be removed from the site. 2. Prior to starting demolition, the Contractor and Owner/Engineer shall jointly visit the

areas of demolition and the Owner/Engineer will designate those items that are to remain the property of the Owner.

3. Equipment and material designated by the Owner, as remaining the property of the Owner, shall be removed from the structure and hauled to a designated location on the site and stored for the Owner’s use. Store on wood runners raised above the surrounding grade and cover with weather resistant covering and tie securely or store inside Owner furnished storage as directed by the Owner/Engineer.

4. Take necessary precautions in removing Owner designated property to prevent damage during the demolition process. Remove steel structural members by unbolting, cutting welds, or cutting rivet heads and punching shanks through holes. Do not use a cutting torch to separate the Owner’s equipment or material unless approved by the Owner/Engineer.

5. Generally, items to be salvaged, shall be removed in one piece or in a manner that does not impact their reuse. Loose components may be removed separately. Controls and electrical equipment may be removed from the equipment and handled separately. Large units may be handled separately. Salvaged piping shall be taken apart at flanges or fittings and removed in sections.

M. Material removed from the construction site during demolition, and any equipment not otherwise designated to remain the property of the Owner in accordance with the pre-demolition identification process shall become the property of the Contractor, and shall be promptly removed from the construction site.

N. The Contractor shall refurbish and replace any existing facility to be left in place which is damaged by the demolition operations at no additional expense to the Owner. The repair of such damage shall leave the parts in a condition at least equal to that found at the start of the Work.

3.3 CLEANING AND REPAIR

A. Clean and repair existing materials and equipment which remain or are to be reused.

B. Panelboards: Clean exposed surfaces and check tightness of electrical connections. Replace damaged circuit breakers and provide closure plates for vacant positions. Provide typed circuit directory showing revised circuiting arrangement.

END OF SECTION

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POWER SYSTEM STUDY Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16105 POWER SYSTEM STUDY.DOCX

SECTION 16105 POWER SYSTEM STUDY

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The Contractor shall provide a Power System Study for the electrical power system, including a Short Circuit Study, Coordination Study, Arc Flash Hazard Study, and a Motor Starting Voltage Drop Study. A Load Flow Study shall be supplemented with appropriate load factors, by the Study Engineer, in consultation with the Owner/Engineer.

B. The electrical power system shall be deemed to include the utility company’s transformer, the Owner’s entire power distribution system which provides power to MCCs 7, 8 and 9. The study shall include the main switchgear and all other MCCs, switchboards and panelboards fed from the main switchgear in addition to MCCs 7,8 and 9. The Plant has other electrical services feeding loads in other parts of the plant, which are excluded from the scope of this study. Included in the study are all existing and new system components, including the modifications to MCCs 7, 8 and 9, and all manufacturer-provided control panels. If present, include any on-site standby generation. The short circuit and coordination study reports shall provide an evaluation of the electrical power systems and the model numbers and settings of the protective relays, circuit breakers, or devices and metering or motor monitoring devices for setting by the Contractor. The Study shall include settings for all motor protective relays and electric system monitoring devices, and as stated above all OEM-provided control panels, both existing and new.

C. The Contractor shall include the use of his own forces to obtain all pertinent data necessary for the successful completion of the Power System Studies, including information on all existing and new equipment and wiring pertinent to the Study. This shall be interpreted to include all cable and raceway data, data for new and existing motors, data from all existing and/or new switchgear, motor control centers, panel boards, and separately mounted fuses, starters and circuit breakers. Obtain all existing or new protective device information to include all present settings. The Contractor shall obtain any needed data or information from Contract Documents, various suppliers, the Electric Utility and from conducting his own field investigations. If, in his field investigations, the Contractor encounters conflicts between the Contract Documents and the field conditions, the Contractor shall immediately notify the Owner/Engineer for a resolution to the conflict. Copies of the data obtained, shall be organized and submitted to the Owner/Engineer at the same time of transmittal to the Study Engineer, to show that all the requested data gathering work has been completed.

D. Arc Flash Warning Labels shall be applied to each item of equipment specified above, including the service entrance equipment, switchboard, MCCs, switchboards, panelboards and control panels whether existing, modified, or new. Refer to the reference power system one line diagram which further depicts the scope of the work. The reference one line is not to be taken to be all inclusive, of every item. As specified above, the Contractor shall use his own forces to fully investigate each item which is powered by the service supplying MCCs 7, 8 and 0.

1.2 RELATED WORK

A. The related work, associated with this Section, shall include all Sections of the Specifications, and the Contract Drawings.

B. The Contractor shall diligently prosecute the work of providing the information required, to the Study Engineer, particularly that information required from the Contractor’s electrical equipment suppliers.

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1.3 SUBMITTALS

A. The Contractor shall, not later than three (3) weeks after Contract Award, provide a submittal of the name and qualifications of the Study Engineer, for approval.

B. The Contractor shall provide two submittals: 1. Short Circuit Submittal: The first submittal shall consist only of the Short Circuit Study

results, based upon sound engineering reasonable assumptions, where known values are not available. This submittal shall be used by the Study Engineer to ascertain the short circuit current rating of the related equipment.

2. Preliminary Full Study Submittal: The second submittal shall consist of all study sections specified herein, with recommendations from the Study Engineer for corrections or improvements which are of benefit to the Owner. This submittal shall be made for approved prior to any shop drawing submittal being reviewed for electrical equipment for which the results of this preliminary study are required. The submittal and approval of the Preliminary Study is a critical milestone in the Contractor’s Construction Schedule. Failure to submit an acceptable study in a timely manner may delay the Project Schedule. No exceptions will be made for the specified sequence of the submittal of the Study prior to the submittal of shop drawings, and any delays caused by a late submittal of the Study will not be a cause for the Engineer / Owner to allow any extension of the Contract Time or Contract Price.

3. Final Full Study Submittal: The final submittal shall be the Final Submittal as defined in this Section. The Contractor is hereby advised that, no electrical equipment for which the results of the final study are required, shall be energized until such results have been reviewed and approved by the Engineer / Owner, and applied to such electrical equipment, and certified as Settings Complete by the manufacturer’s field representative.

C. The Contractor shall, upon completion of the studies, submit the studies for approval to the Owner/Engineer. The study submittal shall include all of the input and output data files in electronic format for use directly with the specified study software. The Study shall include an actual size sample of an Arc Flash and Shock Hazard label with typical information shown. The Contractor shall allow not less than three (3) calendar weeks for review of the both the Preliminary and Final Studies by the Owner/Engineer. The submittal shall not contain unresolved questions, conflicts or selective device coordination conflicts. A submittal containing such questions or conflicts will be returned unreviewed, and shall not be resubmitted until such questions or conflicts have been resolved. Delays in the Contractor’s Construction Schedule due to the submittal of unacceptable Power System Studies will not be a cause for the Engineer / Owner to approve any changes in the Contract Time or Contract Price.

D. The completed, sealed, and signed studies, with all known issues resolved, shall be submitted to the Owner/Engineer for approval, not less than thirty (30) days prior to site delivery of any equipment containing protective devices requiring selections and settings for certification by the manufacturer. Final copies shall be in electronic form (Adobe PDF formatted files). SKM data files shall be provided at the same time in electronic format.


A. The specified studies shall be in accordance with the latest versions of the following codes and standards. 1. IEEE Standard 1584 – IEEE Guide for Performing Arc-Flash Hazard Calculations,

Including Amendment 1584a-2004. 2. NFPA-70E – 2004 - Standard for Electrical Safety Requirements for Employee

Workplaces. 3. ANSI/NFPA 70 – National Electrical C B. The studies shall be performed using SKM

Power Tools Electrical Engineering Analysis Software for Windows.

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A. The studies shall be performed by an Electrical Engineering Services firm, who is regularly engaged in power system studies. The studies shall be performed by a Licensed Professional Electrical Engineer in the regular employment of the firm with proficiency in electrical power systems engineering and shall seal and sign the final completed power system studies. The Study Engineer shall be licensed to practice engineering in the state where the electric equipment is to be installed.

B. The studies shall be performed using SKM Power Tools Electrical Engineering Analysis Software for Windows; no equal or substitutions will be accepted.

C. The PE shall comply with the Texas State PE Law in the submittal of the Preliminary and Final Studies. The Preliminary Study shall bear the name and registration number of the PE who will be sealing the work along with the statement acceptable to the Texas State PE Board which indicates the work is Preliminary, Not for Construction and is Issued for Review. The final report shall bear the Engineer’s Seal, Registration Number, Original Signature and Date in accordance with the State PE Laws.

1.6 SCHEDULE OF WORK

A. The selection of the Study Engineer shall be performed in a timely manner, in accordance with the time specified, and the Study performed and submitted as specified above.

B. The completed studies, with all known issues resolved, shall be submitted to the Owner/Engineer for approval, as specified above.

PART 2 - STUDIES

2.1 ELECTRICAL ENGINEERING SERVICES FIRMS

A. The work experience resume of the Study Engineers who will be doing the work and the Professional Engineer will be sealing the Final Study shall be submitted along with his / her PE registration number in the State where the equipment is to be installed. Subject to compliance with the Contract Documents, the following services firms are acceptable: 1. Cutler Hammer Engineering Services 2. General Electric Co. Engineering Services 3. Schneider Electric Engineering Services 4. Allen Bradley Co. Engineering Services

2.2 SHORT CIRCUIT AND COORDINATION STUDY

A. Provide a complete short circuit study. Include three phase, phase-to-ground calculations and X/R ratios. Provide an equipment interrupting or withstand evaluation based on the actual equipment and model numbers provided on this project including any existing equipment modified in any way under this project. The Contractor shall field verify the name plate data of all existing transformers, protective device equipment and the size and length of any existing conductors in series with the new or modified equipment in the Contract. Conductor lengths in concealed conduit shall be estimated to the best of the Contractor’s ability from field observations and any available existing conformed to construction record drawings. Generic devices or values are not acceptable. Normal system operating method, alternate operation, and operations that could result in maximum fault conditions, shall be thoroughly addressed in the study. Provide single phase to ground and three phase to ground fault information. The study shall assume all motors are operating at rated voltage with the exception that motors, clearly identified as "standby," shall not be included. Electrical equipment bus impedances shall be assumed as zero. Short circuit momentary duties and interrupting duties shall be calculated on the basis of maximum available fault current at the switchgear busses, switchboard busses, motor control centers and panelboards. The study shall be performed

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using actual available short circuit currents as obtained from the Electric Utility. An assumption of infinite bus for the purposes of the Preliminary or Final study is not acceptable.

B. Provide a protective device coordination study. The study shall include all electrical equipment provided under this Contract, including Control Panels containing power and protection equipment lighting panels and power panels. The Study shall include any upstream or downstream equipment that has an impact on the Coordination Study. The study shall show transformer damage curves, cable short circuit-withstand curves and motor starting curves. The phase overcurrent and ground fault protection shall be included, as well as settings for all other adjustable protective devices. All motor monitoring relays and protective or monitoring devices that are a part of a supplier’s equipment, such as soft starters or adjustable frequency drives shall be included. Include the last protective device in the Electric Utilities’ system feeding each facility being considered. Include all medium voltage switchgear, distribution switchboards, motor control centers and 480 Volt panelboard main circuit breakers. Complete the short circuit study down to the main breaker or largest feeder on all on all 480 Volt panelboards. Panelboard branch circuit devices need not be considered. The phase overcurrent and ground-fault protection shall be included, as well as settings for all other adjustable protective devices. All motor monitoring relays and protective or monitoring devices that are a part of a supplier’s equipment, such as soft starters or adjustable frequency drives, shall be included. Include the last protective device in the Electric Utilities system feeding each facility being considered. C. Provide an equipment evaluation study to determine the adequacy of the fault bracing of all bus from the panel board level up to the main switchgear or protective device. Include circuit breakers, controllers, surge arresters, busway, switches, and fuses by tabulating and comparing the short circuit ratings of these devices with the available fault currents.

C. Selective device coordination is required between protective devices in equipment specified in each Section of the Electrical Specifications, and between each piece of electrical equipment, including existing equipment, supplied for this project. If the Study Engineer, in the course of his work, determines that selective coordination cannot be obtained in or between pieces of existing and new equipment as specified, he shall immediately notify the Contractor, provide his supporting information to the Contractor, who shall transmit the information to the Owner/Engineer for resolution of the problem.

D. As a minimum, each short circuit study shall include the following: 1. One-Line Diagram: The presentation of the One Line Diagram shall be on one or more

22 x 34-inch drawings with match lines if on multiple sheets, using font sizes which are easily readable. a. Location and function of each protective device in the system, such as relays,

direct-acting trips, fuses, etc. b. Type designation, current rating, range or adjustment, manufacturer's style and

catalog number for all protective devices. c. Power and voltage ratings, impedance, primary and secondary connections and

impedances of all transformers. Use the ratings of the actual transformers being provided where available. The Final Study shall use the name plate information on the transformers provided. Generic transformer information on new transformers in the final study is not acceptable. Use the actual name plate information on all existing transformers. Generic transformer data is not acceptable on existing transformers in any Study.

d. Type, manufacturer, and ratio of all instrument transformers energizing each relay. The Contractor shall field verify this information on all existing protective devices which are in series with the new equipment provided under this Contract.

e. Nameplate ratings of all motors and generators with their sub transient reactance. The Contractor shall field verify the name plate information of all existing generator providing power to the new equipment, and shall field verify the name plate motor information on all motors connected to the bus of existing equipment which is in series with the new equipment.

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f. Sources of short circuit currents such as utility ties, generators, synchronous motors, and induction motors. Provide short circuit studies using each source of power separately. The study shall determine if there is sufficient short circuit current to adequately cause interruption of a protective device using the weaker power source (typically local generation), and shall determine if the equipment can safely interrupt the fault if the greater power source is connected. Additional short circuit calculations shall include emergency as well as normal switching conditions as well as normal and emergency power sources described here in.

g. All significant circuit elements such as transformers, cables, breakers, fuses, reactors, etc. shall be included.

h. The time-current setting of existing adjustable relays and direct-acting trips, if applicable. The Contractor shall field verify the information as specified herein.

i. The Contractor shall arrange for the shutdown of the equipment requiring field verification with the Owner and shall perform their investigations at a time, including after hours, which do not significantly interrupt the Owner’s process operations.

2. Impedance Diagram: The presentation of the Impedance Diagram shall be on one or more 22 x 34-inch drawings with match lines if on multiple sheets, using font sizes which are easily readable. a. Available MVA or impedance from the utility company. b. Local generated capacity impedance. c. Transformer and/or reactor impedances. d. Cable impedances. e. System voltages. f. Grounding scheme (resistance grounding, solid grounding, or no grounding).

3. Calculations: a. Determine the paths and situations where short circuit currents are the greatest.

Assume bolted faults and calculate the 3-phase and line-to-ground short circuits of each case.

b. Calculate the maximum and minimum fault currents.

E. Provide Time-Current Curves (TCC) on 8-1/2 X 11 log-log paper. The Time Current Curves shall be presented in series only. Parallel branches shall not appear on the same TCC presentation. Do not put more than one branch of protective devices on any one coordination curve. Show a maximum of 5 devices in series on one TCC. Include a one-line diagram and the names of each protective device in the branch on the coordination curve drawing. Use the same color for the same protective device appearing on different TCC presentations. Provide separate drawings for ground fault coordination curves. Use the names designated in the Contract Documents. Include motor starting curves and transformer inrush and damage curves, and cable short circuit withstand curves.

2.3 ARC FLASH HAZARD STUDY

A. The Power System Study shall include an Arc Flash Hazard Study that shall present the level of arc flash hazard for each item of electrical equipment, and the appropriate level of protection required per OSHA standards.

B. The analysis shall be performed with the aid of computer software intended for the purpose, in order to calculate Arc-Flash Incident Energy (AFIE) levels and flash protection boundary distances.

C. The analysis shall be performed under each possible condition and shall identify the worst-case Arc-Flash condition. The preliminary report shall describe, when applicable, how these conditions differ from worst-case bolted fault conditions.

D. The calculations shall be performed in accordance with IEEE 1584-2004 and safe approach requirements determined in accordance with NFPA-70E-2004.

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E. Results of the Analysis shall be submitted in tabular form, and shall include, device or bus name, bolted fault and arcing fault current levels, flash protection boundary distances, personal-protective equipment and AFIE levels.

F. After approval of the Study, The Study Engineer shall provide the Arc Flash Hazard Warning Labels and oversee the Contractor as he affixes the required labels for each item of electrical equipment furnished on the project and for each item of existing equipment for which the arc flash hazard has changed. A typical warning sign shall be submitted with the Study for approval, and as shown below. 1. Flash Hazard Protection Boundary. 2. Limited Approach Boundary. 3. Restricted Boundary. 4. Prohibited Boundary. 5. Incident Energy Level. 6. Required Personal Protective Equipment Class. 7. Type of Fire Rated Clothing.

G. Size of each label shall be not less than 8 inches wide and 6 inches tall.

2.4 MOTOR STARTING VOLTAGE DROP STUDY

A. The motor starting study shall be provided for low voltage motors over 100 HP, full voltage across-the-line started, and for low voltage motors 500 HP and up which are reduced voltage started. Medium motors 500 HP and up full voltage across-the-line started and motors 1500 HP and up reduced voltage started shall be included. Motors started on [variable] [adjustable] frequency drives may not be included.

B. The study shall select the largest motor on a bus and shall assume all other motors on that bus are running. Where a Main-Tie-Main bus configuration is present, the study shall be done with both Main breakers closed and the Tie breaker open, and with one Main open and the Tie breaker closed.

C. Where the Utility feeders are feeding the switchgear, the study shall be done for each feeder based on the actual system impedance for each utility feeder.

D. A motor starting analysis shall be made where on-site standby generation is available to power the MCC using only the available power from the generator. If the generator has been sized to run only part of the load, then the system shall be modeled with only that part of the load running. The generator voltage drop and frequency drop during motor starting shall be modeled and included in the study report.

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PART 3 - EXECUTION

3.1 FIELD SERVICES

A. Sign Installation Certification 1. When the sign installation is complete, the Contractor, the Contractor’s Study Engineer

and the Owner/Engineer shall jointly inspect the locations and to provide to the Owner/Engineer’s satisfaction that signs are installed in all of the recommended locations indicated in the Study.

B. Training 1. The Contractor shall provide the services of the Arc-Flash Training Engineer, for a period

of not less than one eight (8) hour working day, to conduct a training program for the Owner’s personnel, in the care, application and use of protective personal equipment, described by the warning signs installed on the project. The training program shall be conducted at a location onsite determined by the Owner, and shall include specific equipment locations as may be required for instruction. Applicable information from the Study shall be provided to the attendees. Submit a detailed class syllabus to the Engineer/Owner for review and approval prior to holding the training class.

2. The Contractor shall provide the services of the Power System Study Engineer, for a period of not less than one eight (8) hour day, to conduct a power system operations training program for the Owner’s personnel, in the safe operation of the power system. Both new and existing switchgear which is in series with the new equipment shall be included. The safe operation training shall include Kirk Key Operations, power system switching to avoid configurations which may exceed equipment short circuit ratings, or may cause other undesirable or dangerous issues if certain circuits are paralleled. Provide handout materials including one line diagrams, and O&M information for each person in attendance. Submit a detailed class syllabus to the Engineer/Owner for review and approval prior to holding the training class.

C. The cost of Field Services shall be included in the Contract Price.

D. The Owner reserves the right to videotape the training for the Owner’s use. In addition, the Contractor shall provide the services of a professional photographer and shall provide a video recording of the training session. The Contractor shall provide the Engineer with one copy and the Owner with three copies of the video recording of the presentation on a DVD.

END OF SECTION

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RACEWAYS, BOXES AND FITTINGS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16110 RACEWAYS, BOXES AND FITTINGS.DOCX

SECTION 16110 RACEWAYS, BOXES AND FITTINGS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish and install complete raceway systems as shown on the Drawings and as specified herein. A raceway system shall consist of materials designed expressly for containing wires and cables, including but not limited to, conduit, device bodies, conduit bodies, raceway boxes, and related materials.

B. The Bid Price shall be in complete compliance with the Contact Documents. Any exception shall be included in the bid with a detailed explanation that clearly indicates the paragraph of this Specification and / or the item in the Drawings to which the exception applies. The Contractor shall explain in detail the reasons for the exception. The inclusion of an exception and its explanation as specified shall not constitute any obligation on the part of the Engineer / Owner to accept the Bid Price with the exception.

C. This Specification shall have precedence over any conflict in the bidder’s submittals and / or descriptive information and the Contract Documents unless an exception is made at the time of bidding as specified herein, and the bid price is accepted with the bidder’s exception by the Engineer / Owner.

D. The Contractor shall provide all tools, equipment, supplies, and shall perform all labor required to install the equipment specified in the Contract Documents in order to install, test, and place into satisfactory operation in the time specified for completion in the Contract Documents. Failure of any of the Contractors sub-contractors or suppliers to perform the work as specified shall not constitute an acceptable reason for the Owner to grant any change in the Contract Price or additions to the Contract Time.

E. In some cases, raceways and conductors are shown on schedules. Raceways and conductors that are listed on the raceway and conductor schedules are generally not shown on the Drawings, except where they are required to pass through a restricted or designated space. Raceways indicated to be run "exposed" on the schedules shall be run near the ceilings or along the walls of the areas through which they pass and shall be routed to avoid conflicts with HVAC ducts, cranes and hoists, lighting fixtures, doors and hatches, etc. Raceways indicated to be run concealed shall be run in the center of concrete floor slabs, in partitions, or above hung ceilings, as required.

F. Provide a complete raceway system, wire and field connections for all motors, motor controllers, control devices, control panels and electrical equipment furnished under other Divisions. The Contractor shall coordinate his construction schedule and electrical interface with the supplier of electrical equipment specified under other Divisions as required by the Contract Documents.

G. Provide a complete raceway system, wiring and terminations for all field mounted instruments furnished and mounted under other Divisions, including process instrumentation primary elements, transmitters, local indicators and control panels. Lightning and surge protection equipment wiring at process instrumentation transmitters. Install vendor furnished cables specified under other Divisions as required by the Contract Documents.

H. Provide a complete raceway system for the Data Cables and specialty cable systems, including those furnished under other Divisions. Install the Data Cables and other specialty cable systems, in accordance with the system manufacturers' installation instructions. Review the raceway layout, prior to installation, with the Process Control System supplier and the cable manufacturer to ensure raceway compatibility with the systems and materials being furnished. Where redundant cables are furnished, install the cables in separate raceways as required by the Contract Documents.

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I. The Contractor may re-use existing concealed raceways as indicated on the drawings. The Engineer has, to the extent possible by observation, has indicated the presence of concealed raceways which may be used, however the responsibility to verify those raceways lies entirely with the Contractor, who shall field verify their usability prior to bidding. Should the indicated raceways not be usable, then the Contractor shall provide exposed or concealed raceways to provide a complete raceway system with no change in contract price permitted.

J. The Contractor may reuse exposed raceways with modifications and and extensions as required to provide a complete raceway system as specified. Exposed raceways which are to be reused may only be reused if the meet the raceway specifications in the type and material specified for new raceways. New raceways or modified existing raceways shall be routed such that they do not block access to any enclosures or equipment that would interfere with replacement or maintenance, nor shall raceways block doors or windows or be installed such that they present any hazard or nuisance to the Owner’s staff for egress, operation or maintenance.

K. Where equipment is shown or specified to be removed and replaced or demolished, the Contractor shall remove all associated exposed conduits back to their source or to the point of entrance to a concealed portion where the conduits are inaccessible. At the point of entry to a concealed portion, the conduits shall be capped and tagged with their destination point. The Contractor’s conformed to construction record drawings shall clearly show all concealed conduits which are still usable and indicate the location of each end along with the tag designation that was placed on the concealed raceway. Exposed raceways passing through walls shall be removed and the hole patched and painted to match the existing structure. Exposed raceways which enter existing wire ways which are remaining shall have the holes plugged in a manner to maintain the NEMA rating of the wire way. All conductors which are associated with equipment shown to be demolished shall be completely removed from the raceway system back to their source.

1.2 RELATED WORK


B. Section 16033 Cast-In-Place Concrete for Electrical Applications

C. Section 16045 Electrical Support Hardware

D. Section 16120 Wires and Cables (600 Volt Maximum)

E. Section 16600 Underground System

F. Process Equipment Division 11 Specifications

G. Instrumentation Equipment Division 17 Specifications

H. Mechanical Equipment Division 15 Specifications

I. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

J. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different

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equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submit to the Owner/Engineer, in accordance with Division 1, the manufacturers' names and product designation or catalog numbers of all materials specified. 1. Cut sheets for each individual item shall be submitted. 2. Each cut sheet shall be clearly marked to indicate the item submitted and/or mark out

items which are not being submitted for approval. Submittals not clearly marked will be returned with the indication REVISE AND RESUBMIT as a minimum or other indications per the specifications as warranted.

B. Submit to the Owner/Engineer, certification that the electricians installing the PVC coated conduit have a 5-year minimum experience, in the installation of the product.

C. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NFPA 70 – National Electrical Code (NEC) 2. NFPA 70E – Standard For Electrical Safety in the Workplace 3. UL 6A – Electrical Rigid Metal Conduit 4. ANSI C80.5 – Electrical Rigid Aluminum Conduit 5. UL 514B – Outlet Bodies

B. All equipment components and completed assemblies specified in this Section of the Specifications shall bear the appropriate label of Underwriters Laboratories.



B. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly. All assemblies shall be of the same manufacturer.

C. The Contractor’s installer of materials specified herein, shall have a minimum of five (5) years’ experience in the installation of each type of material. Proof of experience shall be submitted, upon request of the Owner/Engineer, prior to installation.

D. Used materials are unacceptable, will be rejected and shall be removed from the job site. Used materials, if installed, shall be removed and replaced with new materials. If new materials are installed with used materials, and the removal of the used materials renders the new materials in an unacceptable condition, such as new conductors installed in used raceway components, (determined by the Engineer/Owner alone) then the new materials shall be removed along with the used materials and replaced. No increase in the Contract Price nor in Contract Time will be allowed.

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A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner/Engineer upon delivery of the equipment, an approved copy of all such submittals. Delivery of incomplete constructed equipment, or equipment which failed any factory tests, will not be permitted.


C. Materials shall not be stored exposed to sunlight. Materials stored outdoors shall be completely covered.

D. Materials showing signs of previous use, jobsite storage at another location, or exposure to the elements or other damage will be rejected.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition.

PART 2 - PRODUCTS

2.1 GENERAL

A. Raceways and fittings shall be as shown on the Drawings, with a minimum 3/4” trade size.

B. Where Equipment or Instrumentation device entries are less than 3/4 inch, provide an REA12SA, Cooper Crouse Hinds or equal, for aluminum raceways and ADAPT ADU302930, REDAPT or equal, for 316 stainless applications.

C. Circuit layouts are not intended to show the number of fittings, exact routing or other installation details. Exposed conduit routings are shown to indicate the presence of the raceway not its exact route. Not all raceways are shown on the plan views. Other raceway requirements are shown on one line diagrams, raiser diagrams and interface wiring diagrams. Where ever the need for circuits and raceways are indicated, the contractor shall provide them and field route from source to load in the manner specified. Furnish all labor and materials necessary to install and place in satisfactory operation all power, lighting and other electrical systems shown.

D. Raceways and conductors for lighting, switches, receptacles and other miscellaneous low voltage power and signal systems as specified are not shown on the Drawings. Raceways and conductors shall be provided as required for a complete and operating system. Refer to riser diagrams for signal system wiring. Homeruns, as shown on the Drawings, are to assist the Contractor in identifying raceways to be run exposed and raceways to be run concealed. Raceways installed exposed shall be near the ceiling or along walls of the areas through which they pass and shall be routed to avoid conflicts with HVAC ducts, cranes hoists, monorails, equipment hatches, doors, windows, etc. Raceways installed concealed shall be run in the center of concrete floor slabs, above suspended ceilings, or in partitions as required. In some cases, existing concealed raceways may be reused and in other cases concealed raceways both single runs and duct banks shall be provided as indicated or where found to be necessary to complete the installation as specified.

E. The Contractor shall run all conduit and wire to RTU and/or PLC termination cabinets, where designated on the Drawings. The conduit and wire as shown on the interface drawings may not necessarily be shown on the floor plan.

F. Install conductors carrying low voltage signals (typically twisted shielded pair cables) in raceways totally separate from all other raceways containing power or 120-volt control

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conductors. Fiber optic cables shall also be routed in raceways totally separate from all other raceways caring any other metallic conductors.

G. Raceways and conductors for thermostats controlling HVAC unit heaters, exhaust fans and similar equipment are not shown on the Drawings. Provide raceways and conductors between the thermostats, the HVAC equipment and the motor starters for a complete and operating system. All raceways and power conductors shall be in accordance with Division 16. Raceways shall be installed concealed in all finished space and may be installed concealed or exposed in process spaces. Refer to the HVAC drawings for the locations of the thermostats and controls.

2.2 CONDUIT RACEWAY

A. PVC Coated Rigid Aluminum Conduit (CRMC) 1. PVC coated rigid aluminum conduit shall have a minimum 0.040-in thick, polyvinyl

chloride coating permanently bonded to rigid aluminum conduit and an internal chemically cured urethane or enamel coating. Rigid aluminum conduit shall be as manufactured by the Allied Tube and Conduit Corp.; Wheatland Tube Co.; Triangle PWC Inc. or T&B Ocal. The ends of all couplings, fittings, etc. shall have a minimum of one pipe diameter in length of PVC overlap. PVC coated conduit and fittings shall be as manufactured by Perma-Cote, Robroy Industries, Triangle PWC Inc. or Ocal.

2. Elbows and couplings shall be PVC coated by the same manufacturer supplying the conduit PVC coating system. Elbows and couplings used with PVC coated conduit shall be furnished with a PVC coating bonded to the aluminum, the same thickness as used on the coated aluminum conduit.

B. Liquid tight Aluminum Flexible Metal Conduit (LFMC) 1. Liquid tight aluminum flexible metal conduit shall have an interlocked aluminum core,

PVC jacket rated for 60 degrees Canada meeting NEC Article 351, as manufactured by the Anaconda Metal Hose Div.; Southwire; Anaconda American Brass Co.; American Flexible Conduit Co., Inc.; Universal Metal Hose Co. or ALFLEX.

2. Fittings used with liquid tight flexible aluminum conduit shall be copper-free aluminum and shall conform to FEDSPEC AA50552, and UL-514B.

C. Aluminum Flexible Metal Conduit (FMC) 1. Aluminum flexible metal conduit shall have an interlocked aluminum core, meeting NEC

Article 348, UL 1and Federal Specification WW-C-566C, as manufactured by the Anaconda Metal Hose Div.; Southwire; Anaconda American Brass Co.; American Flexible Conduit Co., Inc.; or Universal Metal Hose Co.

2. Fittings used with aluminum flexible metal conduit shall be copper-free aluminum shall conform to FEDSPEC AA50552.

D. Rigid Aluminum Conduit (RMC) 1. Rigid Aluminum conduit shall be extruded from AA 6063 alloy in temper designation T-1

and shall conform to FED Spec WW-C-540C, ANSI C80.5 and UL 6A. Rigid aluminum conduit and fittings shall be as manufactured by Wheatland Tube Company, or Allied.

E. Rigid PVC Schedule 40 Conduit (RNC} 1. Schedule 40 PVC Rigid Nonmetallic Conduit (RNC) shall be designed for use

underground as described in the NEC, resistant to sunlight. Conduits shall be provided with bell ends. PVC raceway systems shall be assembled by application of the manufacturer’s-provided or recommended glue. The conduits and fittings shall be manufactured to NEMA TC-2, Federal Specification WC1094A and UL 651 specifications. Fittings shall be manufactured to NEMA TC-3, Federal Specification WC1094A and UL 514B. Conduit shall have a UL Label. Conduit shall be Rocky Mountain Colby, Carlon, or Kraloy.

F. Rigid PVC Schedule 80 Conduit (RNC) 1. Schedule 80 PVC Rigid Nonmetallic Conduit (RNC) shall be designed for use above

ground and underground as described in the NEC, resistant to sunlight. Conduits shall

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be provided with bell ends. PVC raceway systems shall be assembled by application of the manufacturer’s-provided or recommended glue. The conduits and fittings shall be manufactured to NEMA TC-2, Federal Specification WC1094A and UL 651 specifications. Fittings shall be manufactured to NEMA TC-3, Federal Specification WC1094A and UL 514B. Conduit shall have a UL Label. Conduit shall be Rocky Mountain Colby, Carlon, or Kraloy.

2.3 WIREWAYS

A. All wire ways shall be NEMA 4X 316 stainless steel, with gasketed hinged covers and stainless steel latches. Wireway shall have two Breather/Drains for each 10ft of wire way. Breather/Drain shall be located in the bottom, near the ends of the wire way. Wire way shall have integral welded mounting lugs. Bolted-on mounting lugs are unacceptable. Provide quick-release luggage type latches, 3-point handle-operated latches or ¼ - turn latches with 316 stainless steel handles. Latch systems requiring tools to operate are NOT acceptable. Boxes rated for NEC classified areas may have tool-operated latch system if no other type meets UL standards. Wire way shall be as manufactured by Industrial Enclosure Corporation, Cooper B Line, or approved equal. Breather/Drains shall be Cooper Crouse-Hinds Type ECD18-316 stainless steel, or approved equal

2.4 RACEWAY BOXES

A. Boxes specified herein, including terminal boxes, junction boxes and pull boxes, are for use with raceway systems only, but include switch, receptacle and lighting housings. Boxes used for housing electrical and instrumentation equipment, other than terminal boxes, shall be as described elsewhere in these Specifications. All raceway boxes shall be provided with a common ground point and UL rated. All wall mounted boxes shall have integral welded-on mounting lugs or feet. Bond on mounting feet is unacceptable. Floor-mounted boxes shall have a support stand fabricated from the same material as the box it supports. Provide quick-release luggage type latches, 3-point handle-operated latches or ¼ - turn latches with 316 stainless steel handles. Latch systems requiring tools to operate are NOT acceptable. Boxes rated for NEC classified areas may have tool-operated latch system if no other type meets UL standards.

B. Enclosure interior mounting panels shall be secured with stainless steel hardware and shall be fabricated from 316 stainless steel or aluminum. All hardware used to attach components shall be 316 stainless steel, and shall be installed in drilled and tapped holes. Self-taping screws are not acceptable.

C. Classified Areas, NEMA 7/4X (Class 1, Division 1, Groups A, B, C, and D, or as defined in NFPA 70). Boxes shall be constructed as follows: 1. Copper free cast aluminum body and cover 2. Stainless steel hinges 3. Watertight neoprene gasket 4. Stainless steel cover bolts and washers. 5. Manufacturers

a. Cooper Crouse Hinds Type EJB, Style C b. Appleton Electric Type AJBEW

D. Chemical Rooms. NEMA 4X constructed as follows: 1. PVC or Fiberglass reinforced polyester body and door. 2. UV inhibitors 3. 316 stainless steel luggage type quick release latches, or three-point latch system with

all components 316 stainless steel. Latch systems requiring tools to open or close are unacceptable.

4. Manufacturers a. Hoffman Polypro b. Hubbell-Wiegmann Non-Metallic

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E. NEMA 4X Aluminum - use only where specified, required or shown on the Drawings, shall be constructed as follows: 1. Type 5052 aluminum, body and door 2. Stainless steel continuous hinge 3. Foam in-place gasket 4. 316 stainless steel single point quarter turn latches with 316 stainless steel operating

handles – plastic handles are unacceptable - (20”x24” and below). All others shall be provided with a 3-point latch system with all components 316 stainless steel. Latch systems requiring tools to open or close are unacceptable.

5. Manufacturers a. Hoffman Comline b. EMF Company c. NEMA Enclosures Company d. Hammond Company

F. NEMA 12 are, in general not acceptable. They may be used only where specified, required or specifically shown to be required on the Drawings shall be constructed as follows: 1. Type 5052 aluminum, body and door 2. Stainless steel continuous hinge 3. Foam in-place gasket 4. 316 stainless steel single point quarter turn latches with 316 stainless steel operating


5. Manufacturers a. Hoffman Comline b. EMF Company c. NEMA Enclosures Company d. Hammond Company

G. NEMA 4X 316 Stainless Steel enclosures (for all other locations). 1. Type 316 stainless steel, body and door 2. Stainless steel continuous hinge 3. Foam in-place gasket 4. 316 stainless steel single point quarter turn latches with 316 stainless steel operating


5. Mounting feet for self-standing enclosures 6. Manufacturers

a. Hoffman Concept Series b. EMF Company c. NEMA Enclosures Company d. Hammond Company

H. NEMA 1 or NEMA 1A boxes shall not be used.

I. Malleable iron boxes shall not be used.

2.5 DEVICE BOXES

A. Device boxes, switch, receptacle, etc., shall be copper free cast aluminum, and shall have tapered, threaded, hubs, with integral bushings. Boxes shall have internal grounding screw, and a minimum of two mounting feet. Boxes shall be type FD, Cooper Crouse-Hinds, Appleton or approved equal.

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2.6 CONDUIT OUTLET BODIES

A. For conduits up to and including 2-1/2”, conduit outlet bodies and covers shall be copper-free aluminum, with captive screw-clamp cover, neoprene gasket and stainless steel screws and clamps, Cooper Crouse-Hinds Form 7 with Mark 7 wedge-nut cover, Appleton, or approved equal. For conduits larger than 2-1/2”, junction boxes shall be used.

B. For Class 1 Division 11 areas, all outlet boxes and covers shall be EA Series by Crouse Hinds, or approved equal. Rated NEMA 7/4X.

2.7 CONDUIT HUBS

A. Conduit hubs for use on raceway system pull and junction boxes shall be watertight, threaded aluminum, insulated throat, 316 stainless steel grounding screw, as manufactured by T&B H150GRA Series, or approved equal.

2.8 GROUNDING BUSHINGS

A. Grounding bushings shall be insulated lay-in lug grounding bushings with tin-plated copper grounding path. Bushings shall have integrally molded noncombustible phenolic insulated surfaces rated 150°C. Each bushing shall be furnished with a plastic insert cap and grounding lug. The size of the lug shall be sufficient to accommodate the maximum ground wire size required by the NEC for the application. All non-aluminum metallic hardware shall be 316 stainless steel. Bushings shall be O-Z/Gedney Type ABLG, or approved equal.

2.9 RACEWAY SEALANT

A. Raceway sealant for use in the sealing of raceway hubs, entering or terminating in boxes or enclosures where such sealing is shown or specified, shall be 3M 1000NS Watertight Sealant, or approved equal.

2.10 CONDUIT PENETRATION SEALS

A. Conduit wall and floor seals shall be series CSM as manufactured by the O.Z./Gedney Co., or equal. 1. Type CSML-XXXP shall be used for all applications that do not require a recessed

sealing bushing. 2. Type CSMI-XXXP shall be used for all applications that require a recessed sealing

bushing.

2.11 EXPANSION-DEFLECTION COUPLING

A. Combination expansion-deflection fittings with 3/4” axial expansion and contraction movement, 3/4” parallel misalignment movement, and up to 30 degrees of angular movement in any direction. It shall be of copper-free aluminum, with exterior bonding jumper of tinned copper braid and 316 stainless grounding straps, Cooper Crouse-Hinds Model XD as manufactured by the Crouse--Hinds Co., or equal. Nylon tie wraps are not acceptable.

2.12 EXPANSION FITTINGS

A. Expansion fittings shall be, 8” movement, copper-free aluminum, with exterior bonding jumper of tinned copper braid and 316 stainless grounding straps, Type XJGSA as manufactured by Crouse-Hinds Co., or approved equal, with internal grounding. Nylon tie wraps are not acceptable.

2.13 EXPLOSION-PROOF SEALS, BREATHERS AND DRAINS

A. Explosion proof fittings shall be designed for Class 1 Division 1, Group D, hazardous locations. Fittings shall be of copper-free aluminum, consist of seals, breathers and drains of type ED, as

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required for the application. Fittings shall be as manufactured by the Crouse-Hinds Co.; Appleton Electric Co.; O.Z./Gedney Co., or equal.

2.14 KELLUMS GRIPS

A. Kellums grips to support cables shall be of 316 stainless steel.

2.15 CONDUIT MOUNTING EQUIPMENT

A. All pull and junction box supports, spacers, conduit support rods, clamps, hangers, channel, nut, bolts, washers, etc. and shall be made of 316 stainless steel. Nylon tie wraps are not acceptable.

2.16 CONDUIT IDENTIFICATION TAGGING

A. The Contractor shall use the tagging formats for conduits as shown on the Drawings or shall copy and continue the format currently used where not shown. Where modifications or additions are made to existing equipment, the Contractor shall replace existing tags with new modified tags.

B. Conduit identification plates shall be embossed stainless steel with stainless steel band, permanently secured to the conduit without screws. Nylon tie wraps are not acceptable.

C. Identification plates shall be as manufactured by the Panduit Corp. or equal.

PART 3 - EXECUTION


A. Installer shall be specialized in installing PVC coated conduit with minimum 5 years documented experience. Experience documentation shall include training. Training shall be submitted for approval prior to beginning work on this project.

3.2 RACEWAY APPLICATIONS

A. Unless exact locations are shown on the Drawings, the Contractor shall coordinate the placement of raceway systems and related components with other trades and existing installations.

B. Raceway Systems for the installation of Fiber Optic Cables shall not contain conduit bodies, device boxes, or raceway boxes containing less than twelve (12) inches of bend radius.

C. Unless shown on the Drawings or specified otherwise, the raceway type installed with respect to the location shall be as follows, including all materials:

Raceway System Location 1. Rigid Galvanized (RSC) Type Not acceptable for use on this Project

2. PVC Coated Aluminum (CRMC) Type All embedded raceway bends, underground duct

bank bends of more than 20 degrees, and all raceway stub-ups to a minimum of 6” above finished floor or grade. Use in Chlorine and Caustic rooms where shown or otherwise specified.

3. Liquidtight Flexible Aluminum (LFMC) Type Raceway connection to vibrating equipment, and as shown on the Drawings in all areas.

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4. Rigid Non-metallic, Schedule 40 PVC (RNC) Type

Underground encased in red dyed reinforced concrete.

5. Rigid Non-metallic, Schedule 80 PVC (RNC) Type

Use to protect single grounding electrode conductors or lightning protection system down lead conductors in locations where the conductors are installed exposed and are subject to physical damage. In other location use only as shown on the drawings or otherwise specifically specified.

6. Flexible Aluminum (FMC) Type Fixture whip connection to lighting fixtures in NEMA 12 areas (maximum 3-ft). BX or AC type prefabricated cables are not permitted. Installation in any wet, damp, outdoor or area where process equipment is located is prohibited.

7. Aluminum Rigid Metal (RMC) Type All above grade areas, except for concrete embedded and those areas described in Locations 2 through 6 above.

D. All conduit of a given type shall be the product of one manufacturer.

3.3 BOX APPLICATIONS

A. All raceway junction boxes, pull and terminal boxes shall have NEMA ratings for the location in which they are installed, and as specified herein.

B. For all raceway boxes, the distance between each raceway entry inside the box and the opposite wall of the box shall not be less than eight times the metric designator (trade size) of the largest raceway in a row. This distance shall be increased for additional entries by the amount of the sum of the diameters of all other raceway entries in the same row on the same wall of the box. Each row shall be calculated individually, and the single row that provides the maximum distance shall be used.

C. Exposed switch, receptacle and lighting outlet boxes and conduit fittings shall be cast aluminum.

D. All boxes shall be provided with factory mounting lugs. Drilling through the back of any box or enclosure is prohibited, and if so installed, shall be removed and replaced, with no increase in the Contract Price or Construction Schedule. All boxes shall be installed with a minimum of ¼-inch air space between the back of the box and the wall or back panel on which it is installed. The space may be created with a number of 316 stainless steel washers or may be mounted using 316 stainless steel slotted channel.

E. No penetrations shall be made in the top of boxes in wet locations.

3.4 DEVICE BOX APPLICATIONS

A. Device boxes shall be used for mounting wiring devices such as receptacles, switches, thermostats, lighting and other permanently mounted devices. All device boxes shall be installed with a minimum of ¼-inch air space between the back of the box and the wall or back panel on which it is installed. The space may be created with a number of 316 stainless steel washers or may be mounted using 316 stainless steel slotted channel. Anchor to the wall or back panel using the mounting feet. Drilling the box is prohibited Drilled boxes will be rejected and shall be removed and replaced at contractor’s expense.

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3.5 CONDULET APPLICATIONS

A. Condulet bodies may be used on conduits up to and including 2-1/2”, except where junction boxes are shown or otherwise specified. For conduits larger than 2-1/2”, junction boxes shall be used.

B. Condulet bodies shall not be used in fiber optic cable raceways unless specifically designed for and UL listed for use in fiber optics cable installations.

C. Condulet bodies are prohibited in raceway systems containing shielded medium voltage cables.

3.6 CONDUIT HUB APPLICATIONS

A. Unless specifically stated herein or described on the Drawings, all raceways shall terminate at an outlet with a conduit hub. Locknut or double locknut terminations will not be permitted.

B. When conduits contain equipment grounding conductors the wire shall be grounded to the hub(s) associated with that grounding conductor.

3.7 INSULATED GROUNDING BUSHING APPLICATIONS

A. Insulated grounding bushings shall be used to terminate raceways where the raceways enter pad-mounted electrical equipment or switchgear from the bottom where there is no wall or floor pan on which to anchor or terminate the raceway.

B. All other raceways shall terminate on enclosures with a conduit hub, except for NEMA 7/4X areas.

C. Grounding bushing caps shall remain on the bushing until the wire is ready to be pulled.

3.8 CONDUIT FITTINGS APPLICATIONS

A. Combination expansion-deflection fittings shall be installed where conduits cross structure expansion joints, and where installed in exposed conduit runs such that the distance between expansion-deflection fittings does not exceed one hundred fifty (150) feet of conduit run. Expansion-deflection fittings are acceptable in indoor locations out of exposure to direct sunlight or other outdoor locations which are shaded.

B. Expansion-deflection fittings are not acceptable for use outdoors unless approved in writing on a case-by-case basis from the Engineer/Owner. Where combination expansion-deflection fittings with exposed non-metallic sections, are approved by the Engineer/Owner for use where exposed to sunlight or other outdoor locations which are shaded, an aluminum wrap shall be installed loosely over the non-metallic portion, extending at least 2” beyond the ends. The wrap shall be loosely secured, to permit movement, with at least two 316 SS fasteners. Nylon tie-wraps are not acceptable

C. On exposed conduit transitions from underground to above ground, where the earth has been disturbed to a depth of more than ten (10) feet, an expansion fitting, with a minimum of 6” available movement, shall be installed on the exposed side of the transition, in lieu of a combination expansion-deflection fitting.

3.9 CONDUIT PENETRATION SEALS APPLICATIONS

A. Conduit wall seals shall be used where underground conduits penetrate walls or at other locations shown on the Drawings.

B. Conduit sealing bushings shall be used to seal conduit ends exposed to the weather and at other locations shown on the Drawings.

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3.10 EXPLOSION-PROOF SEALS, BREATHERS AND DRAINS APPLICATIONS

A. Fittings consisting of sealing fittings, breathers, drains, with sealing compound and fiber, as specified herein, shall be used as required to meet all the requirements of the National Electrical Code.

3.11 CONDUIT TAG APPLICATIONS

A. All conduits shall be tagged within 1ft. of the entry of equipment, and wall and floor penetrations.

B. The Contractor shall tag all underground conduits and ducts at all locations, exiting and entering from underground, including manholes and handholes.

3.12 RACEWAY SEALING

A. Where raceways enter junction boxes or control panels containing electrical or instrumentation equipment, all entrances shall be of the hub type and sealed with Raceway Sealant, as specified herein.


3.13 PVC RACEWAY TO PVC COATED ALUMINUM RACEWAY TRANSITIONS

A. Where a transition is made from PVC raceway to PVC coated aluminum raceway, the PVC raceway shall terminate in a female adapter. A PVC coated aluminum male threaded end, a PVC coated aluminum male adapter, shall be threaded into the female threaded PVC adaptor. After tightening securely, the PVC-coated aluminum and PVC threaded adaptor shall be double layered with 2 in. vinyl electrical tape, for a distance of 2 inches each side of the threaded joint to prevent any contact between any exposed aluminum threads and concrete.

3.14 RACEWAY INSTALLATION

A. Do not install pull wires and conductors until the raceway system is in place. No wire shall be installed between outlet points, junction points or splicing points, until raceway sections are complete, and raceway covers installed for protection of conductors from damage or exposure to the elements. Conductors installed into incomplete raceway systems are considered improperly installed and are in violation of the NEC. The occurrence of wire installed in an incomplete installation, shall require the removal of such conductors from the project site, and replacement of the conductors at with no increase in Contract Time or Schedule. The raceway system shall be completed and inspected by the Engineer/Owner, before new conductors are installed.

B. No conduit smaller than 3/4-in electrical trade size, shall be used, nor shall any have more than the equivalent of three 90 degree bends in any one run. Pull boxes shall be provided as necessary. Conduit reducers which are the same type of the raceway shall be installed where manufacturer-provided enclosures are not available with conduit hubs larger than ½-inch at the enclosure to terminate ¾-inch conduit. The raceway fill shall be adjusted to accommodate the smaller opening in the manufacturer-provided enclosure. The Contractor shall notify the Engineer/Owner prior to the installation of the raceway into enclosures with openings smaller than the specified minimum. Raceways installed without notice are considered unacceptable and may be required to be removed at the Engineer’s/Owner’s discretion.

C. All raceways, installed underground, shall be installed in accordance with Section 16600 Underground System, and be a minimum size of 2”C.

D. Where raceways enter or leave the raceway system, where the raceway origin or termination, could be subjected to the entry of moisture, rain or liquid of any type, particularly where the termination of such raceways terminate in any equipment, new or existing at a lower elevation, such raceways shall be tightly sealed, using Watertight Sealant, at the higher elevation, both before and after the installation of cables, such that there shall be no entry of water or moisture

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to the Raceway System at any time. Any damage to new or existing equipment, due to the entrance of moisture from unsealed raceways, shall be corrected by complete replacement of such equipment, at no cost to the Owner. Cleaning or drying of such damaged equipment will not be acceptable.

E. Conduit supports, other than for underground raceways, shall be spaced at intervals of 8-ft or less, as required by the NEC and as required to obtain rigid construction. Conduits shall be supported near the entry into any enclosure in accordance with the NEC. Conduits shall not be used to support other conduits, nor shall conduits be supported from cable tray.

F. Single conduits shall be supported by means of one-hole pipe clamps in combination with one-screw back plates, to raise conduits from the surface. Multiple runs of conduits shall be supported on trapeze type hangers with horizontal members and threaded hanger rods. The rods shall be not less than 3/8-in diameter. Surface mounted panel boxes, junction boxes, conduit, etc shall be supported by strut, to provide a minimum of 1/2-in clearance between wall and equipment.

G. Conduit hangers shall be attached to structural steel by means of beam or channel clamps. Where attached to concrete surfaces, concrete anchors shall be as specified in Section 16045 Electrical Support Hardware.

H. No raceways or electrical equipment shall be attached to or supported from, sheet metal walls.

I. All conduits on exposed work shall be run at right angles to and parallel with the surrounding wall and shall conform to the form of the ceiling. No diagonal runs will be allowed. Bends in parallel conduit runs shall be concentric. Offsets in conduit runs shall all be done at the same point and shall all be the same angle so the entire installation appears to be parallel or concentric at every point. All conduits shall be run perfectly straight and true.

J. Conduits terminated into enclosures shall be perpendicular to the walls where flexible liquidtight or rigid conduits are required. The use of short sealtight elbow fittings for such terminations will not be permitted, except for connections to instrumentation transmitters, where multiple penetrations are required.

K. Conduits shall be installed using threaded fittings. Running threads will not be permitted.

L. All conduit fittings on PVC conduit shall be of the glued type.

M. Liquid tight flexible aluminum conduit shall be used for the primary and secondary of transformers, generator terminations and other equipment where vibration is present. Use in other locations is not permitted, except for connections to instrumentation transmitters, where multiple penetrations are required. Liquid tight flexible aluminum conduit shall have a maximum length not greater than that of a factory manufactured long radius elbow of the conduit size being used. The maximum bending radius shall not be less than that shown in the NEC Chapter 9, Table 2, “Other Bends”. BX or AC type prefabricated cables will not be permitted.

N. Conduits installed which are not in compliance with these requirements shall be removed and reinstalled at the Engineer’s/Owner’s discretion. If conductors are installed when the improper installation is discovered, the Contractor shall remove the conductors from the raceway, discard them and remove them from the job site, shall replace them, re-terminate and retag them, retest each conductor in accordance with the specifications and retest the function of the system which they connect in its entirety. No increase in Contract Time or Schedule shall be allowed.

O. Where conduits pass through openings in walls or floor slabs, the remaining openings shall be sealed against the passage of flame and smoke.

P. Conduit ends exposed to the weather or corrosive gases shall be sealed with conduit sealing bushings.

Q. Raceways terminating in Control Panels or enclosures outdoors or any wet or damp location or any location where plant process equipment is located, or any location not otherwise specifically designated as a dry electrical room, control room or office space, which contain

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electrical equipment or terminal blocks, shall not enter from the top of the enclosure, and the raceway shall be sealed with a watertight sealant as specified herein. Enclosures entered from the top where top entry is prohibited, will be rejected and shall be removed and replaced regardless of the Division which contains the specification for the enclosure. The use of UL Listed conduit closures to restore the NEMA rating of the enclosure will not be accepted. Conduit entering the top of the enclosures shall be removed and re-routed to enter the enclosure from the side or bottom. Conductors installed in top entering conduits shall be pulled back to the nearest conduit body or junction box and re-routed with the conduit, provided the conductors are long enough to be re-terminated. Conductors found to be insufficient in length to be re-terminated shall be completely removed and replaced, re-tested, re-tagged, re-tested and the control function of the panel shall be re-tested. If the enclosure is provided by an OEM, the enclosure and its contents shall be returned to the OEM for a new enclosure. No increase in Contract Price nor increase in Contract Time will be allowed the Contractor for making these corrections.

R. All conduits from external sources entering or leaving a multiple compartment enclosure shall be stubbed up into the bottom horizontal wireway or other manufacturer designated area, directly below the vertical section in which the conductors are to be terminated. Conduits entering from cable tray shall be stubbed into the upper section.

S. Conduit sealing and drain fittings shall be installed in areas designated as NEMA 4X or classified areas, and all building penetrations as specified.

T. A conduit identification plate shall be installed on all power, instrumentation, alarm and control conduits at each end of the run and at intermediate junction boxes, manholes, etc. Conduit plates shall be installed before conductors are pulled into conduits. Exact identification plate location shall be coordinated with the Owner/Engineer at the time of installation to provide uniformity of placement and ease of reading. Conduit numbers shall be exactly as shown on the Drawings.

U. Mandrels shall be pulled through all existing conduits that will be reused and through all new conduits 2-in in diameter and larger prior to installing conductors.

V. 3/16-in polypropylene pull lines shall be installed in all new conduits noted as spares or designated for future equipment.

W. All conduit that may under any circumstance contain liquids such as water, condensation, liquid chemicals, etc, shall be arranged to drain away from the equipment served. If conduit drainage is not possible, conduit seals shall be used to plug the conduits at the point of attachment to the equipment.

X. Conduits shall not cross pipe shafts, access hatches or vent duct openings. They shall be routed to avoid such present or future openings in floor or ceiling construction.

Y. The use of running threads is prohibited. Where such threads are necessary, a 3-piece union shall be used.

Z. Conduits passing from heated to unheated spaces, exterior spaces, refrigerated spaces, cold air plenums, etc, shall be sealed with Watertight Sealant as specified herein.

AA. Conduits shall be located a minimum of 3-in from steam or hot water piping. Where crossings are unavoidable, the conduit shall be kept at least 1-in from the covering of the pipe crossed.

BB. Conduits terminating at a cable tray shall be supported independently from the cable tray. Provide a conduit support within 1-ft of the cable tray. The weight of the conduit shall not bear on the cable tray.

CC. All changes of direction on PVC coated aluminum conduit greater than 20 degrees shall be accomplished using long radius bends. Any field bends shall be made using equipment designed to prevent damage to the PVC coating.

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END OF SECTION

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WIRES AND CABLES (1000 VOLT MAXIMUM) Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16120 WIRES AND CABLES (1000 VOLT MAXIMUM).DOCX

SECTION 16120 WIRES AND CABLES (1000 VOLT MAXIMUM)

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish, install and test all wire, cable and appurtenances as shown on the Drawings and as specified herein.


C. This Specification shall have precedence over any conflict in the bidders submittals and / or descriptive information and the Contract Documents unless an exception is made at the time of bidding as specified herein, and the bid price is accepted with the bidder’s exception by the Engineer / Owner.


1.2 RELATED WORK

A. Provide and install all 4-20mA signal circuits, process control wiring, signal wiring to field instruments, RTU and/or PLC input and output wiring and other field wiring and cables.

B. Section 16110 Raceways, Boxes and Fittings

C. Section 16600 Underground System

D. Process Equipment Division 11 Specifications

E. Instrumentation Equipment Division 17 Specifications

F. Mechanical Equipment Division 15 Specifications

G. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

H. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

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1.3 SUBMITTALS

A. Shop Drawings 1. Submit catalog data of all wire and cable, connectors and accessories, specified under

this Section with all selections, options and exceptions clearly indicated. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

B. Certified Tests 1. Submit a test report of all installed wire insulation tests.

C. Operation and Maintenance Manuals 1. Submit Operation and Maintenance Manuals containing installation and maintenance

instructions for splice and termination kits.

D. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NFPA 70 – National Electrical Code (NEC) 2. NEMA WC-5 – Thermoplastic-Insulated Wire and Cable for the Transmission and

Distribution of Electrical Energy 3. ANSI/TIA/EIA 606A – Standard for telecommunications Infrastructure


A. The general construction of the wire, cables and the insulation material used shall be similar to that used for cable of the same size and rating in continuous production for at least 15 years and successfully operating in the field in substantial quantities.

B. Wire and cable with a manufacture date of greater than twelve (12) months previous will not be acceptable.

C. Wire and cable shall be in new condition, with the manufacturer’s packaging intact, stored indoors since manufacture, and shall not have been subjected to the weather. Date of manufacture shall be clearly visible on each reel.

D. The manufacturer of these materials shall have produced similar electrical materials for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.


A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner/Engineer upon delivery of the equipment, an approved copy of all such submittals. Delivery of incomplete constructed equipment, or equipment which failed any factory tests, will not be permitted.,

B. Check for reels not completely restrained, reels with interlocking flanges or broken flanges, damaged reel covering or any other indication of damage. Do not drop reels from any height.

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C. Unload reels using a sling and spreader bar. Roll reels in the direction of the arrows shown on the reel and on surfaces free of obstructions that could damage the wire and cable.

D. Store cable on a solid, well drained location. Cover cable reels with plastic sheeting or tarpaulin. Do not lay reels flat.

1.7 WARRANTY

A. The Manufacturer shall warrant the wiring and installation to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty, the Manufacturer shall promptly furnish all material and labor necessary to return the installation to new operating condition.

PART 2 - PRODUCTS

2.1 GENERAL

A. Wires and cables shall be of annealed, 98 percent conductivity, soft drawn tinned copper.

B. All conductors shall be Class B stranded.

C. Except for control, signal and instrumentation circuits, wire smaller than No. 12 AWG shall not be used.

2.2 BUILDING WIRE

A. All building wire shall be tinned stranded copper conductors, Type XHHW-2, as manufactured by Southwire, General Cable or Okonite.

2.3 VARIABLE FREQUENCY DRIVE CABLE

A. Cable for use with VFDs between the output terminals and the motor terminals shall be symmetrical design, three stranded Class D, tinned copper, circuit conductors with XLPE insulation, three bare copper grounds, 100% shields with 50% overlap, and overall PVC jacket. Cable shall be 2000 volt, UL 1277 Type TC, XHHW-2 rated, 90-degree C., IEEE 1202/383. Cable shall be as manufactured by General Cable, Southwire or Okonite.

2.4 TRAY CABLE

A. Cable for tray use shall be tinned stranded copper conductors, Type XHHW-2 insulation, rated as UL Type TC cable. Cable shall be sunlight resistant and approved for direct burial. Cable shall be as manufactured by Southwire, General Cable or Okonite.

2.5 GROUNDING ELECTRODE CONDUCTOR

A. Grounding electrode conductor shall be tinned stranded copper conductor, Type XHHW-2 with green insulation, as manufactured by Southwire, General Cable, or Okonite.

2.6 BONDING JUMPER

A. Bonding Jumper shall be bare tinned stranded copper conductor, as manufactured by Southwire, General Cable, or Okonite.

2.7 CONTROL WIRE AND CABLE

A. Control wire shall be tinned copper, No.14 AWG 600V, NEC Type XHHW-2 PVC outer jacket overall, Type TC, UL rated for underground wet location, as manufactured by Okonite, General Cable, or Southwire.

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B. Multi-conductor control cable, shall be stranded, tinned, No.14 AWG 600V, NEC Type XHHW-2 insulated, PVC outer jacket overall, Type TC, UL rated for underground wet location, as manufactured by Southwire, Okonite, or General Cable.

2.8 INSTRUMENTATION CABLE

A. Cables for 4-20 ma, R.T.D., potentiometer and similar signals shall be PLTC rated and shall be: 1. Single pair cable:

Conductors: 2 #16 stranded, tinned and twisted on 2-in lay Insulation: PVC with 600 volt rated, 90 degrees C rating Shield: 100 percent mylar tape with drain wire Jacket: PVC with manufacturer’s identification Misc: UL1685 listed for underground wet location use Manufacturers: Okonite, Southwire, General Cable or Belden or approved equal.

2. Three conductor (triad) cable: Conductors: 3 #16 stranded, tinned and twisted on 2-in lay Insulation: PVC with 600 volt rated, 90 degrees C rating Shield: 100 percent mylar tape with drain wire Jacket: PVC with manufacturer’s identification Misc: UL1685 listed for underground wet location use Manufacturers: Okonite, Southwire, General Cable, or Belden.

3. Multiple pair cables (where shown on the Drawings): Conductor: Multiple pairs, #16 stranded, tinned and twisted on a 2-in lay Insulation: PVC with 600 volt rated, 90 degrees C rating Shield: Individual pairs shielded with 100 percent mylar tape and drain wire Jacket: PVC with manufacturer’s identification Misc: UL1685 listed for underground wet location use Manufacturers: Okonite, Southwire, General Cable or Belden.

2.9 2.09 COMMUNICATION CABLES

A. Cables for Ethernet and RS485 shall be rated and shall be: 1. Category 5e above Grade shielded Cable

Conductors: 4 bonded pair 24AWG Bare Copper Insulation: Polyolefin Shield: 100 percent aluminum foil polyester tape with drain wire Jacket: PVC with 600 volt rated and manufacturer’s identification Misc.: UL21047 and UL1666 listed for indoor and dry locations use Manufacturers: Belden 7957A.

2. Category 5e above Grade un-shielded Cable Conductors: 4 bonded pair 24AWG Bare Copper Insulation: Polyolefin Jacket: PVC with 300 volt rated and manufacturer’s identification NEC CMR Misc.: UL1666 listed for indoor and dry locations use Manufacturers: Belden 7923A.

3. Category 6 above Grade shielded Cable Conductors: 4 bonded pair 23AWG Bare Copper Insulation: Polypropylene Shield: 100 percent aluminum foil polyester tape with drain wire Jacket: PVC with 600 volt rated and manufacturer’s identification Transmission Standards: Category 6 - TIA 568.C.2 NEC CMR Flame Test Method: UL1666 Vertical Riser listed for indoor and dry locations use Manufacturers: Belden 7953A.

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4. Category 6 above Grade un-shielded Cable Conductors: 4 bonded pair 23AWG Bare Copper Insulation: Polyolefin Jacket: PVC with 300 volt rated and manufacturer’s identification Transmission Standards: Category 6 - TIA 568.C.2 Nominal Velocity of Propagation: 72 % Flame Test Method: UL1666 Vertical Riser listed for indoor and dry locations use Manufacturers: Belden 7940A.

5. Category 5e below Grade shielded Cable Conductors: 4 pair 24AWG Bare Copper Insulation: Polyolefin Shield: 100 percent aluminum foil polyester tape with drain wire Jacket: LLPE (Linear Low Density Polyethylene) with 300 volt rated and

manufacturer’s identification Misc.: NEMA WC-63.1, listed for outdoor and wet locations use Water Blocking compound and listed for direct bury applications. Manufacturers: Belden 7934A, [or] BlackBox.

6. 485 Communications Cable Conductors: 1 pair 24AWG Tinned Copper Insulation: Polyethylene Shield: 100 percent aluminum foil polyester tape with tinned copper drain wire Jacket: PVC with 300 volt rated and manufacturer’s identification Misc.: UL2919 listed for indoor and dry locations use Manufacturers: Belden 9841.

2.10 TERMINATION MATERIALS

A. Power Conductors: Termination materials, of conductors at equipment, shall be as specified in the relevant equipment Section.

B. Control and Instrumentation Conductors (including graphic panel, alarm, low and high level signals): Termination connectors shall be of the set screw, tongue type, UL Listed for stranded conductor termination, as manufactured by Phoenix Contact, Entrelec, Allen Bradley, or equal.

C. Motor Conductors: Motor connections with conductors # 12 AWG up to # 6 AWG shall be ring type compression terminations on the motor leads and secured with bolt, nut and spring washer. Connections shall be -30C rubber insulated, half lap, and two layers minimum of Scotch 33 or equal vinyl tape. Motor terminations for conductors # 8 AWG and larger shall be in accordance with paragraph “Lugs and Connectors” below. Motors provided on this project per specification 16150 (26 05 50) and / or 16151 (26 05 51) shall have motor terminals enclosures with bus and NEMA 1-hole or 2-hole pads to accommodate the conductor terminals specified herein.

D. Lugs and Connectors 1. All lugs and connectors shall be tin plated copper and shall be crimped type, with

standard industry tooling. Lugs and connectors shall match the wire size where used, and shall be clearly identified and color coded on the connector. All connections shall be made for stranded wire and shall be made electrically and mechanically secured. The lugs and connectors shall have a current carrying capacity equal to the conductors for which they are rated and meet UL 486 requirements for 75 degrees C. Lugs for # 12 AWG up to # 6 AWG shall be ring terminals. Conductors # 4 AWG and larger shall be two-hole long barrel lugs with NEMA spacing. All lugs shall be the closed end construction to exclude moisture migration into the cable conductor.

2.11 SPLICE MATERIALS

A. Power Conductors: Circuits shall be pulled from terminal to terminal, without splicing, except where splicing is shown on the Drawings. No other splicing will be permitted. For wires sizes

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#8 and smaller, provide color coded wire nuts, with metal inserts, 3M or Ideal, rubber insulated with half lap and two layers minimum of Scotch 33 tape. For wires greater than #8 AWG, provide a heat shrink insulated, color-coded, die-crimped splice lug, T&B 54XXX, or equal, rubber insulated, with half lap and two layers minimum of Scotch 33 tape.

B. Control and Instrumentation Conductors (including graphic panel, alarm, low and high level signals): No splicing of control and instrumentation conductors will be permitted.

2.12 WALL AND FLOOR SLAB OPENING SEALS

A. Wall and floor slab openings shall be sealed with "FLAME-SAFE" as manufactured by the Thomas & Betts Corp. or equal.

2.13 WIRE AND CABLE TAGS

A. The Contractor shall use the tagging formats for wire and cable as shown on the Drawings. Where modifications or additions are made to existing wire and cable runs, the Contractor shall replace existing tags with new modified tags.

B. Wire tags for wire sizes, #2 AWG and smaller, shall be heat shrink type Raychem TMS-SCE, or approved equal with the tag numbers typed with an indelible marking process. Character size shall be a minimum of 1/8" in height. Hand written tags shall not be acceptable. Where ends are not available, attach cable tags with nylon tie cord.

C. Tags for wires larger than #2 AWG and all cables shall be thermally printed polyethylene type, Brady TLS 2200 or approved equal, nylon zip tied in accordance with the manufacturer’s instructions.

D. Tags relying on adhesives or taped-on markers are not acceptable.

E. Tagging shall be done in accordance with the execution portion of these Specifications.

2.14 WIRE COLOR CODE

A. All wire shall be color coded or coded using electrical tape in sizes #8 or greater, where colored insulation is not available. Where tape is used as the identification system, it shall be applied in all junction boxes, manholes and other accessible intermediate locations as well as at each termination.

B. The following coding shall be used:

System Wire Color 1-Phase, 3 Wire Phase A

Phase B Neutral

Black Blue White

208Y/120, Volts 3-Phase, 4 Wire

Phase A Phase B Phase C Neutral

Black Red Blue White

480/277, Volts 3-Phase, 4 Wire

Phase A Phase B Phase C Neutral

Brown Orange Yellow Gray/White with one or more colored stripes

2.15 CABLE TAG COLOR CODE

A. All cable tags shall be white in color with black printing.

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PART 3 - EXECUTION

3.1 GENERAL

A. Do not install pull wires and conductors until the raceway system is in place. No wire shall be installed between outlet points, junction points or splicing points, until raceway sections are complete, and raceway covers installed for protection of conductors from damage or exposure to the elements. The occurrence of wire installed in an incomplete installation, shall require the removal of such conductors from the project site, and completion and inspection of such raceway sections, before new conductors are installed.

B. Installed unapproved wire shall be removed and replaced at no additional cost to the Owner.

C. Completely swab raceway system before installing conductors. Do not use cleaning agents and lubricants which have a deleterious effect on the conductors or their insulation.

D. Pull all conductors into a raceway at one time, using wire pulling lubricant as needed to protect the wire.

E. Except for hand-pulled conductors into raceways, all wire and cable installation shall be installed with tension-monitoring equipment. Where conductors are found to have been installed without tension–monitoring, the conductors and cables shall be immediately removed from the raceways, permanently identified as rejected material, and removed from the jobsite. New conductors and cables shall be reinstalled, tagged and raceways resealed, all at no expense to the Owner.

F. Do not exceed cable manufacturer's recommendations for maximum pulling tensions and minimum bending radii. Where pulling compound is used, use only UL listed compound compatible with the cable outer jacket and with the raceway involved.

G. Tighten all screws and terminal bolts using torque type wrenches and/or drivers to tighten to the inch-pound requirements of the NEC and UL.

H. Where single conductors and cables in manholes, hand holes, vaults, cable trays, and other indicated locations are not wrapped together by some other means such as arc and fireproofing tapes, bundle throughout their exposed length all conductors entering from each conduit with nylon, self-locking, releasable, cable ties placed at intervals not exceeding 4 inches on centers.

I. All wire and cable installed in cable trays shall be UL Listed as Type TC, for cable tray use.

3.2 CONDUCTORS 1000 VOLTS AND BELOW

A. Provide conductor sizes indicated on Drawings, as a minimum.

B. Use crimp connectors on all stranded conductors.

C. Soldered mechanical joints insulated with tape will not be acceptable.

D. Arrange wiring in cabinets and panels neatly cut to proper length, remove surplus wire, and bridle and secure in an acceptable manner. Identify all circuits entering motor control centers or other control cabinets in accordance with the conductor identification system specified herein.

E. Terminate control and instrumentation wiring with methods consistent with terminals provided, and in accordance with terminal manufacturer's instructions.

F. Attach compression lugs, larger than #6 AWG, with a tool specifically designed for that purpose which provides a complete, controlled crimp where the tool will not release until the crimp is complete. Use of plier type crimpers is not acceptable.

G. Cap spare conductors and conductors not terminated with the UL listed end caps.

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H. Where conductors pass through holes or over edges in sheet metal, remove all burrs, chamfer all edges, and install bushings and protective strips of insulating material to protect the conductors.

I. For conductors that will be connected by others, provide at least 6 feet spare conductors in freestanding panels and at least 2 feet spare in other assemblies. Provide additional spare conductor in any particular assembly where it is obvious that more conductor will be needed to reach the termination point.

J. Do not combine power conductors. Do not run signal conductors carrying voltages less than 120 VAC in the same raceway as conductors carrying higher voltages regardless of the insulation rating of the conductors. Do not share neutrals on branch circuits.

3.3 GROUNDING

A. Conduits and other raceways shall contain an equipment grounding conductor whether the raceway is metallic or not. Conduits, motors, cabinets, outlets and other equipment shall be properly grounded in accordance with NEC requirements. Where ground wire is exposed to mechanical damage, install wire in rigid aluminum conduit. Make connections to equipment with solderless connections. Wire connected to the ground rods of the ground mat shall be of the fused type equal to the Cadweld process.

3.4 TERMINATIONS AND SPLICES

A. No splices of wire and cable will be permitted, except where specifically permitted by the Owner/Engineer in writing, or as shown on the Drawings.

B. Power conductors: Terminations shall be made with connectors as specified. Splices, where specifically allowed as stated above, shall be made in a Termination Cabinet (TC).

C. Control Conductors: Splices of control conductors will not be permitted between terminal points. Terminations shall be made with approved terminals as specified.

D. Instrumentation Signal Conductors (including graphic panel, alarm, low and high level signals): Splices of Instrumentation conductors will not be permitted between terminal points. Terminations shall be made with connectors as specified. The shield of pair shielded and triad shielded shall be terminated on terminal strips. Provide dedicated terminal block to every conductor including shields. Double lugging terminations is not acceptable.

3.5 INSTRUMENTATION CABLES

A. Instrumentation cables shall be installed in raceways as specified. Unless specifically shown on the Drawings, all instrumentation circuits shall be installed as single shielded twisted pair cables or single shielded twisted triads. In no case shall a circuit be made up using conductors from different pairs or triads. Triads shall be used wherever three wire circuits are required.

B. Terminal blocks shall be provided at all instrument cable junction boxes, and all circuits shall be identified at such junctions.

C. Shielded instrumentation wire, coaxial cable, data highway cable, discrete I/O, multiple conductor cable, and fiber optic cables shall be run without splices between instruments, terminal boxes, or panels. The shield shall be continuous for the entire run.

D. Shields shall be grounded at the PLC/RTU. Terminal blocks shall be provided for inter-connecting shield drain wires at all junction boxes. Individual circuit shielding shall be provided with its own block.

E. Shield wire shall be wrapped and taped at the transmitter end of the signal run. Before termination, peel back the outer sheath, leaving the shield intact. Wrap the drain wire around the conductors, leaving approximately two inches exposed. Wrap the drain wire with two layers of Scotch 33 tape.

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3.6 WIRE TAGGING

A. All wiring shall be tagged at all termination points and at all major access points in the electrical raceways. A termination point in defined as any point or junction where a wire or cable is physically connected. This includes terminal blocks and device terminals. A major access point to a raceway is defined as any enclosure; box or space designed for wire or cable pulling or inspection and includes pull boxes, manholes, and junction boxes.

B. Wire tags shall show both origination and destination information to allow for a wire or cable to be traced from point in the field. Information regarding its origination shall be shown in parenthesis.

C. For multiconductor cables, both the individual conductors and the overall cable shall be tagged. Conductors that are part of a multiconductor cable shall reference the cable identification number that they are a part of, as well as a unique conductor number within the cable.

3.7 CABLE TAGGING

A. All cables shall be tagged at all termination points and at all major access points in the electrical raceways as defined in the wire tag section of this Specification.

B. The cable tag shall be installed where the cable enters and leaves each access point (e.g., junction box, manhole, etc.). In cases of limited access space, a single tag may be used that shows both equipment tag origination and destination. In the case where the jacket is stripped for terminations, the tag shall be installed at the end of the jacket.

3.8 RACEWAY SEALING

A. Where raceways enter junction boxes or control panels containing electrical or instrumentation equipment, all entrances shall be sealed with 3M 1000NS Watertight Sealant, or approved equal.


3.9 FIELD TESTS

A. Conductors under 600 Volts 1. Perform insulation resistance testing of all power circuits below 1000 volts with a 1000-

volt megger, in accordance with the recommendations of the wire manufacturer. 2. Prepare a written test report of the results and submit to the Owner/Engineer prior to final

inspection. 3. Minimum acceptable value for insulation resistance is 100 megohms for cable lengths

40 feet or less. Lower values shall be acceptable only by the Owner/Engineer's specific written approval. For lengths longer than 40 feet, the minimum megohm value shall be 2000 megohms per foot.

4. Disconnect equipment that might be damaged by this test. Perform tests with all other equipment connected to the circuit.

B. Tests: After instrumentation cable installation and conductor termination by the instrumentation and control supplier, perform tests to ensure that instrumentation cable shields are isolated from ground, except at the grounding point in the instrumentation control panel. Remove all improper grounds.

END OF SECTION

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LIGHT SWITCHES AND RECEPTACLES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16140 LIGHT SWITCHES AND RECEPTACLES.DOCX

SECTION 16140 LIGHT SWITCHES AND RECEPTACLES

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment, and install wiring devices as shown on the Drawings and as specified herein.

B. Provide all interconnecting conduit and branch circuit wiring for receptacle circuits in accordance with the NEC.

1.2 RELATED WORK










J. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Shop Drawings 1. Submit catalog data of all switches, receptacles and other specified items under this

Section, with all options, application locations and exceptions clearly indicated. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

B. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the

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Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. Wiring devices shall comply with the requirements of the National Electrical Code (NEC) and shall be Underwriters Laboratories (UL) labeled.






B. Equipment shall be handled and stored in accordance with manufacturer's instructions.

C. Equipment shall be stored indoors and protected from moisture, dust and other contaminants.

D. Equipment shall not be installed until the location is finished and protected from the elements.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty, the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the Manufacturers listed in each product category are acceptable.

B. The listing of specific manufacturers does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed are not relieved from meeting these specifications in their entirety.

2.2 RATINGS

A. The service voltage, shall be as shown on the Drawings. The overall short circuit withstand and interrupting rating of the equipment and devices shall be equal to or greater than the overall short circuit withstand and interrupting rating of the feeder device immediately upstream of the equipment.

2.3 MATERIALS

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A. Wall switches shall be heavy duty, industrial specification grade, toggle action, flush mounting quiet type. All switches shall conform to the latest revision of Federal Specification WS 896. Wall switches shall be of the following types and manufacturer: 1. Single pole, 20 Amp, 120/277 Volt - Cooper, Catalog No. 2221V, similar to Hubbell, Inc.;

Pass & Seymour, Inc. or equal. 2. Double pole, 20 Amp, 120/277 Volt - Cooper, Catalog No. 2222V, similar by Hubbell,

Inc.; Pass & Seymour, Inc. or equal. 3. Three way, 20 Amp, 120/277 Volt - Cooper, Catalog No. 2223V, similar by Hubbell, Inc.;

Pass & Seymour, Inc. or equal. 4. Four way, 20 Amp, 120/277 Volt - Cooper, Catalog No. 2224V, similar by Hubbell, Inc.;

Pass & Seymour, Inc. or equal. 5. Single pole, 20 Amp, 120/277 Volt - key operated, Cooper Catalog No. AH1191N, similar

by Hubbell, Inc.; Pass & Seymour, Inc. or equal. 6. Single pole, 20 Amp, 120 Volt - red pilot-lighted handle, Cooper, Catalog No. 2221PL,

similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal. 7. Single pole, 20 Amp, 120 Volt, clear lighted handle, Cooper, Catalog No. 2221LTV,

similar by Hubbell, Inc or equal. 8. Momentary contact, three position, 2 circuit, center off - Cooper, Catalog No. 1995V,

similar by Hubbell Inc.; Pass & Seymour, Inc. or equal.

B. Fluorescent wall box dimmer switch for 120/277 Volt control of rapid start fluorescent lamps with a dimming range of 100 percent to .5 percent light for 120 Volt and 100 to 1 percent light for 277 Volt. Dimmer switch controls shall be as manufactured by Lutron Electronics Co., Inc., similar by Lithonia Control Systems; Valmont Electric, Inc. or equal.

C. Explosion-proof single pole factory sealed switches shall be for 20 Amps, 120/277 volts, mounted in copper free aluminum boxes and be similar and equal to Crouse-Hinds EDS Series, similar by Appleton Electric Co.; Killark or equal.

D. Receptacles shall be heavy duty, corrosion resistant, specification grade of the following types and manufacturer or equal. Receptacles shall conform to Fed Spec WC596. 1. Duplex, 20 Amp, 125 Volt, 2 Pole, 3 Wire Grounding, high impact, arc and moisture

resistant yellow nylon construction, heavy nickel plating on metal parts; Cooper, Catalog No. 5362CRY, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

2. Single, 20 Amp, 250 Volt, 2 Pole, 3 Wire; Cooper, Catalog No. 5461GY, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

3. Weatherproof/corrosion resistant single, 20 Amp, 125 Volt, 2 Pole, 3 Wire Grounding Receptacle, as specified above, with die cast aluminum, while-in-use weatherproof cover, Crouse-Hinds Catalog No. WIUMH/V, or similar by Thomas & Betts or equal. Plastic or other non-metallic in-use covers are not acceptable.

4. Weatherproof/corrosion resistant duplex, 20 Amp, 250 Volt, 2 Pole, 3 Wire Grounding Receptacle, as specified above, with die cast aluminum, while-in-use weatherproof cover, Crouse-Hinds Catalog No. WIUMH/V, or similar by Thomas & Betts or equal. Plastic or other non-metallic in-use covers are not acceptable.

5. Clock hanger single, 15 Amp, 125 Volt, 2 Pole, 3 Wire, with hanging hook on device plate. Cooper, Catalog No. 452, similar by Hubbell, Inc.; Pass & Seymour Inc. or equal.

6. Single, corrosion resistant locking, 20 Amp, 125 Volt, 2 Pole, 3 Wire; Cooper, Catalog No. CRL520R and plug Cooper, Catalog No. CRL520P, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

7. Single twist-lock, 30 Amp, 125 Volt, 1 Phase, 3 Wire; Cooper, Catalog No. CRL530R; plug: Cooper, Catalog No. CRL530P, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

8. Single twist-lock, 20 Amp, 250 Volt, 1 Phase, 3 Wire; Cooper, Catalog No. CRL620R; plug: Cooper Catalog No. CRL620P, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

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9. Single twist-lock, 30 Amp, 250 Volt, 1 Phase, 3 Wire; Cooper, Catalog No. CRL630R; plug: Cooper, Catalog No. CRL630P, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

10. Explosion-proof single, 20 Amp, 125 Volt, 1 Phase, 3 Wire; Appleton Electric, Catalog No. EFSC175-2023 and plug, Appleton Electric Catalog No. ECP-2023, similar to Crouse-Hinds; Hubbell Inc or equal.

11. Explosion-proof duplex, 20 Amp, 125 Volt, 1 Phase, 3 Wire; Appleton Electric, Catalog No. EFSC275-2023 and plug, Appleton Electric Catalog No. ECP-2023, similar by Crouse-Hinds; Hubbell, Inc. or equal.

12. Explosion-proof single, 20 Amp, 250 Volt, 1 Phase, 3 Wire; Appleton Electric, Catalog No. EFSC175-20232 and plug, Appleton Electric Catalog No. ECP-20232, similar by Crouse-Hinds; Hubbell Inc or equal.

13. Explosion-proof duplex, 20 Amp, 250 Volt, 1 Phase, 3 Wire; Appleton Electric, Catalog No. EFSC275-20232 and plug, Appleton Electric Catalog No. ECP-20232, similar by Crouse-Hinds; Hubbell, Inc. or equal.

E. Device Plates 1. Plates for indoor flush mounted devices shall be of the required number of gangs for the

application involved and shall be as follows: a. Administration type buildings: Smooth, high impact nylon of the same

manufacturer and color as the device. Final color to be as selected by the Architect.

b. Where permitted in other areas of the plant, flush mounted devices in cement block construction shall be Type 302 high nickel (18-8) stainless steel of the same manufacturer as the devices.

2. Plates for indoor surface mounted device boxes shall be cast metal of the same material as the box, Crouse-Hinds No. DS23G and DS32G, or equal.

3. Oversized plates shall be installed where standard plates do not fully cover the wall opening.

4. Device plates for switches mounted outdoors or indicated as weatherproof shall be gasketed, cast aluminum with provisions for padlocking switches "On" and "Off", Crouse Hinds No. DS185, or equal.

5. Multiple surface mounted devices shall be ganged in a single, common box and provided with an adapter, if necessary, to allow mounting of single gang device plates on multi-gang cast boxes.

6. Engraved device plates shall be provided where required. 7. Weatherproof, gasketed cover for GFI receptacle mounted in a FS/FD box shall be

Cooper, Catalog No. 4501-FS, similar by Hubbell, Inc.; Pass & Seymour, Inc. or equal.

F. Three Phase Power Receptacles 1. Three phase power receptacles and plugs shall be rated for the voltage and current

ratings of the connected load unless otherwise shown on the Drawings. 2. Receptacles and plug housings shall be constructed of copper free aluminum listed to

UL standard 498 for watertight construction. Hardware shall be stainless steel. 3. Performance

a. Maximum working voltage: 600 Volts RMS. b. Dielectric withstand voltage: 3000 Volts. c. Full load break capability at rated current. d. 5000 connect/disconnect cycles at rated voltage and current.

4. Furnish and install one mating plug with each receptacle. 5. Provide the following features:

a. Color coded by voltage. b. One-piece housing/angled back box c. Shrouded pins d. Self-closing gasketed cover. e. Watertight cable entrances/stress relief grips.

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f. Mating keys. g. All current carrying components shall be tin plated including contacts. h. Conductor clamping screws shall be stainless steel.

6. Acceptable manufacturers: a. Hubbell (North American Rated Series II) b. General Electric c. Cooper d. Meltric

G. G. Interlocked Three Phase Power Receptacles 1. Interlocked three phase power receptacles shall include a combination receptacle and a

mechanically interlocked disconnect switch. The two units shall be interlocked to prevent removal or insertion of the plug unless the switch is in the OFF position. The receptacle shall meet the requirements of Power Receptacles specified herein.

2. Provide a matching plug for every unit furnished. 3. Switch, power receptacle and mating plug shall be constructed of copper free aluminum. 4. Assembly shall be listed to UL Standard 498 for watertight- construction. 5. Hardware shall be stainless steel. 6. Performance:

a. Maximum working voltage: 600 Volts RMS. b. Dielectric withstand voltage: 3000 Volts. c. Full load break capability at rated current. d. 5000 connect/disconnect cycles at rated voltage and current.

7. Provide the following features: a. Color coded by voltage. b. One piece housing/angled back box c. Shrouded pins d. Self-closing gasketed cover. e. Watertight cable entrances/stress relief grips. f. Mating keys. g. All current carrying components shall be tin plated including contacts. h. Conductor clamping screws shall be stainless steel.

8. The disconnect switch shall be unfused or fused, as shown on the Drawings, or otherwise specified herein or if required by the NEC, with ratings as hereinbefore specified. Provide lockout provisions on the disconnect switch handle.

9. Acceptable manufacturers: a. Crouse-Hinds b. Appleton c. Killark d. Hubbell

H. 30 Amp, 480 Volt Receptacles 1. Subject to compliance with the Contract Documents, the following Manufacturers are

acceptable: a. Crouse Hinds Arktite style 2, Catalog No. ARE 3423


3. 30 Amp, 480 Volt receptacles shall be 3 Pole, 4 Wire, grounding pin and sleeve type, with circuit breaking capability. The receptacle shall meet the requirements of Power Receptacles specified herein. a. All current carrying components shall be tin plated including contacts. b. Conductor clamping screws shall be stainless steel.

4. Furnish and install one matching plug for each receptacle shown on the Drawings.

I. Welding Receptacles and Disconnect Switches

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1. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: a. Crouse Hinds Arktite Receptacles with Enclosed Safety Switches", Catalog No.

WSR103542. 2. The listing of specific manufacturers above does not imply acceptance of their products

that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety.

3. Welding receptacles and disconnect switches shall be rated 600 Volts, 100 Amp, 3 Pole, 4 Wire, 60 Hz. Receptacle shall be mechanically interlocked with its disconnect switch to prevent breaking the circuit with the receptacle and plug. Ground wire shall be bonded to the plug and receptacle housings. Enclosure type shall be NEMA 4. The receptacle shall meet the requirements of Power Receptacles specified herein. a. All current carrying components shall be tin plated including contacts. b. Conductor clamping screws shall be stainless steel.

4. Furnish and install one matching plug for the welder.

J. Portable Generator Input Receptacle 1. Subject to compliance with the Contract Documents, the following Manufacturers are

acceptable: a. Crouse Hinds Catalog No. 1042S22 with plug, Crouse Hinds Catalog No. APJ

10487S22 2. The listing of specific manufacturers above does not imply acceptance of their products

that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety.

3. Portable generator input receptacle shall be weatherproof, rated for 600 Volts, 100 Amp, 3 Phase, 4 Wire grounding pin and sleeve type with a 15 degree mounting adapter, spring door cover. a. All current carrying components shall be tin plated including contacts. b. Conductor clamping screws shall be stainless steel.

4. Both receptacle and plug shall have reversed contacts.

K. Poke-Thru Service Fittings 1. Poke-thru service fittings shall be installed in a 2-in core drilled hole, fit floor thicknesses

of 2-1/2-in to 7-in and be fire rated. 2. Poke-thru service fittings shall be barriered to handle both high and low tension services

and be designed for both new construction and building retrofit. 3. Service fitting heads shall each contain a 20 Amp, 125 Volt, 2 Pole, 3 Wire duplex

receptacle on one side and provisions for up to 2-25 pair telephone cables on the remaining side.

4. Complete poke-thru services fitting shall be as manufactured by Raceway Components similar by Walker; Square D or equal.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Switches and receptacles shall be installed flush with the finished wall surfaces in areas with stud frame and gypboard construction, in dry areas with cement block construction or when raceways are shown as concealed on the Drawings.

B. Do not install flush mounted devices in areas designated DAMP, WET or WET/CORROSIVE on the Drawings. Provide surface mounted devices in these areas.

C. Provide weatherproof devices covers in areas designated WET or WET/CORROSIVE on the Drawings.

D. Unless otherwise shown on the Drawings, wall switches and other wall mounted controls shall be installed at 4’-6” AFF.

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E. Convenience receptacles shall be 36-in above the floor unless otherwise shown.

F. Convenience receptacles installed outdoors and in rooms where equipment may be hosed down shall be 36-in above floor or grade. Switches shall be ganged together under one cover plate.

G. The location of all devices is shown, in general, on the Drawings and may be varied within reasonable limits so as to avoid any piping or other obstruction without extra cost, subject to the approval of the Owner. Coordinate the installation of the devices for piping and equipment clearance.

H. Convenience receptacles and light switches shall be connected using stranded pig tails and spring fork insulated lugs. Feed-through wiring of receptacles is prohibited.


A. Test wiring devices to ensure electrical continuity of grounding. Energize the circuit to demonstrate compliance with the requirements.

END OF SECTION

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NEMA FRAME INDUCTION MOTORS, 600 VOLTS AND BELOW Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16150 NEMA FRAME INDUCTION MOTORS, 600 VOLTS AND BELOW.DOCX

SECTION 16150 NEMA FRAME INDUCTION MOTORS, 600 VOLTS AND BELOW

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Provide electric motors, accessories, and appurtenances complete and operable, in conformance with the individual driven equipment specifications and other sections of the Contract Documents.


C. This Specification shall have precedence over any conflict in the bidder’s submittals and / or descriptive information and the Contract Documents unless an exception is made at the time of bidding as specified herein, and the bid price is accepted with the bidder’s exception by the Engineer / Owner.


E. The provisions of this Section shall apply to all low voltage NEMA Frame AC squirrel cage induction motors, except as indicated otherwise.

1.2 RELATED WORK


B. Section 16105 Power System Study

C. Section 16120 Wires and Cables (600 Volt Maximum)

D. Section 16475 Low Voltage Enclosed Circuit Breakers and Disconnect Switches

E. Section 16480 Low Voltage Motor Control Centers

F. Section 16481 Low Voltage Motor Controllers

G. Section 16485 Low Voltage Variable Frequency Drives (VFDs)

H. Section 16486 Mechanical Manufacturer’s Provided Control Panels (MEM’s)

I. Process Equipment Division 11 Specifications

J. Instrumentation Equipment Division 17 Specifications

K. Mechanical Equipment Division 15 Specifications

L. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information

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or additional work as may be required in those references, and include such information or work as may be specified.

M. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of the process equipment division of these Specifications, and as specified herein. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

B. Submittals for equipment specified herein shall be made as a part of equipment furnished under other Sections. Individual submittals for equipment specified herein will not be accepted and will be returned unreviewed.

C. Submittals shall also contain information on related equipment to be furnished under this Specification and described in the related sections listed in Related Work above. In accordance with Section 16105 Power System Study listed in the Related Work Sections above, the Contractor shall provide a Certification as part of the submittal, which certifies that all settings and adjustments have been made. Incomplete submittals not containing the required information on the related equipment will be returned as “INCOMPLETE SUBMITTAL – REJECTED. No portion of an INCOMPLETE SUBMITTAL will be Approved or reviewed.

D. The following information shall be submitted with the motor drawings for review. 1. Name of Drive 2. Horsepower of Motor 3. Phase 4. Full Load Efficiency 5. Voltage 6. Full Load Power Factor 7. Speed 8. NEMA Design Starting Torque 9. NEMA Frame and Dimensions 10. Full Load Current 11. Locked Rotor Current 12. Insulation Class 13. Temperature Rise at 1.0 SF 14. Enclosure 15. Bearing life design 16. Special features (i.e., space heaters, stator temperature switches, oversize conduit box

and corrosion resistant features). 17. Nameplate Drawing with Information as listed herein. 18. Lugs and connectors.

E. Suppliers of fractional horsepower motors below frame 143T will not be required to submit operational characteristics.

F. Factory Tests. Submittals shall be made for factory tests as specified above.

G. Field Test Reports. Submittals shall be made for field tests specified herein.

H. Operation and Maintenance Manuals. 1. Operation and maintenance manuals shall include the following information:

a. Manufacturer’s contact address and telephone number for parts and service.

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b. Instruction books and/or leaflets c. Recommended renewal parts list d. Record Documents for the information required by the submitted motor information

above.

I. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. Motors shall be designed, built, and tested in accordance with the latest revision of the following standards: 1. National Electrical Manufacturers Association Inc. (NEMA)

a. NEMA MG1 - Motors and Generators. b. NEMA MG1 Part 9 – Sound Power Linits and Measurement Procedures. c. NEMA MG2 - Safety Standard for Construction and Guide for Selection,

Installation and Use of Electric Motors and Generators. d. NEMA MG3 - Sound Level Prediction for Installed Rotating Electrical Machines.

2. National Fire Protection Association (NFPA) a. NFPA-70 - National Electrical Code.

3. Underwriters Laboratories, Inc. (UL) a. UL-1004 - Electric Motors.

4. Institute of Electrical and Electronics Engineers, Inc. (IEEE) a. IEEE Std 1 - General Principles for Temperature Limits in the Rating of Electric

Equipment. b. IEEE Std 43 - Recommended Practice for Testing Insulation Resistance of

Rotating Machinery. c. NEMA MG1 Part 9 – Sound Power Limits and Measurement Procedures. d. IEEE Std 112 – Standard Test Procedure for Polyphase Induction Motors and

Generators. e. IEEE Std 275 - Recommended Practice for Thermal Evaluation of Insulation

Systems for AC Electric Machinery Employing Form-wound Pre-insulated Stator Coils, Machines Rated 6,900 V and Below.

f. IEEE Std 429 - Standard Test Procedure for the Evaluation of Sealed Insulation Systems for AC Electric Machinery Employing Form-wound Stator Coils.

g. IEEE Std 1349 – Guide for the Application of Electric Motors in Class 1, Div 2 Hazardous Locations.

5. Anti-Friction Bearing Manufacturer's Association Inc. (AFBMA): a. AFBMA-9 & 11 - Load Ratings and Fatigue Life for Roller Bearings.


1.5 DEFINITIONS

A. Motors specified herein are three-phase, squirrel cage induction type for ½ HP and above, and single phase for less than ½ HP, except as specifically specified elsewhere in these Specifications.

B. The word "Drive" shall be construed to mean the driven equipment, i.e. pump, hoist, fan, compressor, or adjustable frequency drive connected with the motor.

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C. If there is inconsistency of size on different Drawing sheets or between Drawings and other sections of Specifications, relating to the horsepower designation, then the larger size shall be required.


A. Motor Compatibility. The Contractor shall satisfy himself that the motor included with the drive is compatible with driven equipment and complies with these Specifications. In the event that the motors described in these Specifications cannot be applied to the application or equipment offered, the Contractor may submit an exception, stating clearly the deviations and the reasons for such deviations. The acceptance or rejection of such deviations shall be at the sole discretion of the Owner/Engineer.

B. When motors are furnished with driven equipment, the driven equipment supplier shall be responsible for mounting the motor and driven equipment as a complete unit, correctly aligned and coupled with the coupling or sheave specified on the driven equipment data sheet, and for designing vibration, special, or unbalanced forces resulting from equipment operation.

C. Motors manufactured more than twenty-four (24) months prior to the date of this Contract will not be acceptable. Date of manufacture, of each motor shall be on the nameplate.



B. Equipment shall be handled and stored in accordance with manufacturer's instructions. Two (2) copies of these instructions shall be included with the equipment at time of shipment, and shall be made available to the Contractor and Owner. The instructions shall include detailed assembly instructions including but not limited to wiring interconnection diagrams, rigging for lifting, skidding, jacking and moving using rolling equipment to place the equipment, bolt torqueing requirements for bus and all other components which require the installation of bolted connections, and instructions for storing the equipment prior to energizing.

C. Protect equipment during shipment, handling, and storage by suitable complete enclosures. Protect equipment from exposure to the elements and keep thoroughly dry.

D. Protect painted surfaces against impact, abrasion, discoloration, and other damage. Repaint damaged painted surfaces to the satisfaction of the Owner/Engineer.

E. If motors are shipped as an integral part of the associated mechanical equipment, the motors shall be stored and handled in accordance with the manufacturer’s instructions

F. If motors are shipped separately, the motor shall be installed in its permanent, finished location shown on the Drawings within fourteen (14) calendar days of arriving onsite. If the equipment cannot be installed within fourteen (14) calendar days, the equipment shall not be delivered to the site, but stored offsite, at the Contractor’s expense, until such time that the site is ready for permanent installation of the equipment. Motors stored off site shall not be included in any pay applications. Payment for motors will not be allowed until delivered to the job site.

G. Provide temporary electrical power and operate space heaters, during storage and after motors are installed in permanent location, until equipment is placed in service. Unless stored in a heated air-conditioned space, space heaters shall be energized within 24 hours of arrival. Failure to energize space heaters as required shall constitute improper storage and the motors are subject to rejection and are subject to be returned to the Factory for inspection and re-testing. Improperly stored motors may be inspected and tested in the field. The choice to return equipment or conduct an inspection and test in the field lie solely with the Engineer / Owner. No pay applications for improperly stored motors will be accepted prior to receiving the

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manufacture’s report of inspection, testing and certification that the motors are acceptable for installation with full warrantee still in force. All expenses to return and re-ship to the job site or inspect and test in the field shall be borne by the Contractor with no change in Contract Price or Contract Time allowed.

H. The motor shaft shall be rotated on a monthly basis, if such is recommended or required by the motor manufacturer; the date recorded, and copies of the record provided to the Owner/Engineer and the manufacturer. The manufacturer shall confirm receipt of the rotation record.

1.8 WARRANTY

A. Where the equipment manufacturer furnishes the motor and control as an integral part of the equipment package, the motor(s) shall have the same warranty as the equipment package. For all other motors, the motor manufacturer shall warrant the motor to be free from defects in material and workmanship for not less than 3 years from date of final acceptance of the associated equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the motor to new operating condition. Any warranty work requiring shipping or transporting of the motor shall be performed by the motor manufacturer, at no expense to the Owner.

PART 2 - PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. General Electric 2. TECO – Westinghouse 3. Baldor Reliant 4. No Equal


2.2 GENERAL REQUIREMENTS

A. Each motor provided shall have an Identification Tag Number, conforming to the numbering system and equipment name shown on the Drawings.

B. Specific motor data such as HP, RPM, enclosure type, etc., is specified under the detailed specification for the mechanical equipment with which the motor is supplied.

C. The motor manufacturer’s nameplates shall be engraved or embossed on stainless steel and fastened to the motor frame with stainless steel screws or drive pins. Nameplates shall indicate clearly all of the items of information enumerated in NEMA Standard MGI, as applicable, including but not limited to the following information: 1. Horsepower (output). 2. RPM at full load. 3. Time rating. 4. Frequency. 5. Number of phases. 6. Model number. 7. Rated voltage. 8. Service factor. 9. Full load amps. 10. Insulation class.

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11. NEMA design letter. 12. NEMA code letter. 13. Temperature Rise at 1.0 SF. 14. NEMA Frame size. 15. Motor Weight 16. Date of manufacture. 17. Thermal protection (if supplied).

D. Where frequent starting occurs, the design for frequent starting duty shall be equal to the duty service required by the driven equipment.

E. Altitude: Under 3300 FT. For applications above 3300 FT, motors shall be specifically designed and certified for operation at the specific altitude.

F. Motors shall have sufficient horsepower and torque capacity to drive the equipment without overloading under all conditions, without exceeding the nameplate rating of the motor and without use of the service factor.

G. Motors shall have a breather drain in each end bracket of the TEFC motor enclosure. Stainless steel automatic breather drains shall be provided in the lowest part of both end brackets to allow drainage of condensation.

H. Motors shall be slide rail mounted for all belt or chain-driven applications.

I. Air inlets and outlets shall be protected by vermin-proof, corrosion resistant louvers. The air inlets shall be located on end or side as required by the application.

J. Motors shall have an oversized, gasketed, cast iron conduit box, field adjustable in 90-degree increments unless the box contains equipment, diagonally split with tapped NPT threaded conduit entrance hole, and shall exceed the minimum volumes defined in IEEE 841-2001. Neoprene conduit box cover gasket and neoprene lead seal gasket with flexible nipples to ensure the seal is maintained as the leads are moved shall be furnished. Provision for grounding shall be provided in the conduit box utilizing a mounted clamp-type lug. Provide the size and number of threaded conduit openings or integral conduit hubs for the conduits containing the motor power conductors. Provide one hole lugs for connection to conductors # 12 AWG through # 8 AWG. Provide termination pads to terminate NEMA 2-hole long barrel lugs for conductors # 6 AWG and larger.

K. Provide separate accessory lead conduit boxes. Minimum size entrance hub shall be ¾”C.

L. Motor frames, end brackets, and conduit box shall be of cast-iron.

M. Provide lifting lugs on the motor frame.

N. Motors shall be NEMA Design B standard, unless otherwise specified in the process equipment division of these Specifications.

O. Service factor shall be 1.15 for all motors. 1. In sizing motors, no portion of a motor’s service factor above 1.0 shall be used in normal

continuous operation of the motor.

P. Motors shall be of the Energy Efficient type, and shall meet or exceed efficiencies as listed in the Table at the end of this Specification.

Q. All motors shall be continuous time rated suitable for operation in a 40 degrees C ambient, unless specified otherwise in the process equipment division of these Specifications.

R. Unless otherwise indicated or specified, motors shall be totally enclosed fan cooled (TEFC), for all applications. See the process equipment division of these Specifications for pumps and other equipment that require additional enclosure requirements.

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S. All TEFC Motors shall have corrosion resistant enclosures, fan, cover, epoxy paint, corrosion resistant fittings and stainless steel or aluminum nameplates similar to “Mill and Chemical”, “Corro-Duty”, “Chemical Processing” motors, or equal.

T. Motors are to be bi-directional. If the fan must be unidirectional, it shall be the motor manufacturer's responsibility to obtain the direction required from the drive manufacturer.

U. Guards 1. Exposed moving parts shall be provided with guards in accordance with the requirements

of OSHA. Guards shall be fabricated of flattened expanded metal screen, 3/4-inch No. 10, to provide visual inspection of moving parts without removal of the guard.

2. Guards shall be galvanized after fabrication and shall be designed to be readily removable to facilitate maintenance of moving parts. Windows shall be provided in the guard for access to the lubricating fittings.

2.3 FRACTIONAL HORSEPOWER MOTORS – LESS THAN ½ HP

A. Motor voltage shall be single phase, 115 V, 60 Hz, unless otherwise shown on the Drawings.

B. Enclosures shall be TEFC or TENV.

C. Motors shall have NEMA standard Class "F" insulation with a maximum temperature rise of 90 C above a 40 C ambient, on a continuous operation or intermittent duty, at nameplate horsepower.

D. Motors shall have a built-in manual or automatic reset thermal protector, or an integrally mounted, enclosed manual reset, motor overload switch.

2.4 MOTORS ½ HP AND LARGER

A. Motor voltage shall be 3 phase, single voltage, as shown on the Drawings, and in compliance with IEEE 841 (Mill & Chemical).

B. Motors shall have NEMA standard Class "F" insulation with a maximum temperature rise of 90 C above a 40 C ambient, on a continuous operation or intermittent duty, at nameplate horsepower (Class B temperature rise).

C. Motors shall have non-hygroscopic encapsulated windings of copper. Motor leads shall be Class F rated, with permanent identification.

D. Motor rotors and assembly, shall be dynamically balanced.

E. Motors less than 15 HP shall have a locked rotor inrush not exceeding MG 1. Motors 15HP and larger shall have a locked rotor inrush kVA` not exceeding Code G (6.29 KVA/HP).

F. Motors shall meet or exceed the Minimum Guaranteed Efficiencies, listed in the Table of Part 4 of this Section, at the approximate nameplate current values at 460 volts.

G. The motor insulation system for motors controlled with variable frequency drives (VFD’s) shall have full capability to handle the common mode voltage conditions imposed by the VFD. Motor insulation system shall conform to all of the requirements of the latest version of NEMA MG1, Part 31 for peak voltage withstand capability.

H. All motors controlled with VFD’s shall have minimum a 1600 Volt rated insulation systems.

I. The critical speed of the shaft and rotor assembly shall exceed the operating speed by a minimum of 10 percent.

J. The no-load sound pressure level, based on the A-weighted scale at 3 feet, when measured in accordance with NEMA MG1 Section 1 Part 9, shall not exceed the values listed in Table 9-1.

K. Vibration limits shall not exceed 0.2-in/sec at any frequency.

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L. Motors shall have a minimum of one grounding pad on each motor frame. Motors larger than 75hp shall have a minimum of two brass grounding pads on each motor frame.

M. Bearings 1. Motors 1/2 through 5 HP shall have permanently lubricated sealed antifriction ball-

bearings with L10 lifetime of 50,000 HRS. 2. Motors larger than 5 HP shall have oil or grease-lubricated antifriction ball-bearings with

L10 lifetime of 50,000 HRS. 3. Vertical motor thrust and guide bearings shall conform to AFBMA standards and shall

have L10 lifetime ratings as specified for ball-bearings of the same horsepower range. Down thrust information shall be provided to the motor manufacturer by the equipment supplier.

4. Anti-friction motor bearings shall be designed to be regreasable and initially shall be filled with grease suitable for the motor ambient temperature specified.

5. Grease lubricated bearings, except those specified to be factory sealed and lubricated, shall be fitted with easily accessible grease supply, flush, drain and relief fittings. Extension tubes shall be used when necessary. Grease supply fittings shall be standard hydraulic type as manufactured by the Alemite Division of the Stewart Warner Corporation.

6. Sealed bearings shall be contact seal (lip) or non-contact labyrinth type.

N. Space Heaters 1. Space heaters shall be supplied with all 3 phase motors and shall conform to the

following: a. Heaters shall be of the cartridge or flexible wrap around type installed within the

motor enclosure adjacent to core iron. Heaters shall be rated for 120 V, single phase with wattage as required. The heater wattage and voltage shall be embossed on the motor nameplate. Power leads for heaters shall be brought out at the motor accessory lead junction box. Provide integral conduit hubs or threaded openings ¾-inch minimum.

O. Stator Temperature Detection 1. Winding temperature detectors of the bi-metallic switch type shall be provided for all

NEMA Frame motors 100 Hp and up. All NEMA Frame motors controlled by variable frequency drives, (VFDs) regardless of horsepower rating shall have winding temperature detectors. Provide the detectors factory installed, and embedded in the windings. Device shall protect the motor against damage from overheating caused by single phasing, overload, high ambient temperature, abnormal voltage, locked rotor, frequent starts or ventilation failure. The switch shall have normally closed contacts. Not less than three detectors shall be furnished with each motor.

2. Wire all temperature detectors to a separate terminal box on the motor. Each detector shall be clearly tagged with the winding which it detects and all detectors shall be terminated on terminal blocks.

2.5 FACTORY TESTING

A. Motors shall be standard motor tested. Except where specific testing or witnessed shop tests are required by the specifications for driven equipment, factory test reports may be copies of routine test reports of electrically duplicate motors. Test report shall indicate test procedure and instrumentation used to measure and record data. Test report shall be certified by the motor manufacturer's test personnel and be submitted to the Engineer for approval.

B. As specified herein, provide a complete test per NEMA MG1 and IEEE Standard 112, consisting of the following: 1. Full Load Heat Run 2. Temperature Test (Actual loading method) 3. Performance Test 4. Locked Rotor Test

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5. No Load Saturation 6. Speed Torque 7. Winding Resistance (A 118 and 43) 8. High Potential 9. Noise Test (A 85)

C. Balance and vibration shall meet NEMA standards MG1-12.05 and MG1-12.06.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The Contractor shall install motors in accordance with the manufacturer’s instructions.

B. Make a visual and mechanical inspection.

C. Check for physical damage.

D. Compare equipment nameplate information with single line diagram and report any discrepancies.

E. Inspect for proper mounting, grounding, connection, and lubrication.

F. Inspect each motor for the proper installation, rated voltage, phase and speed.

G. Check for proper phase and ground connections, Check to see that multi-voltage motors are connected for the proper voltage.

H. Motor connections shall be ring type compression terminations on the motor leads and secured with bolt, nut and spring washer. Connections shall be rubber insulated, half lap and two layers minimum of Scotch 33 tape.

I. All lugs and connectors shall be copper and shall be crimped type, with standard industry tooling. Lugs and connectors shall match the wire size where used, and shall be clearly identified and color coded on the connector. All connections shall be made for stranded wire and shall be made electrically and mechanically secured. The lugs and connectors shall have a current carrying capacity equal to the conductors for which they are rated and meet UL 486 requirements for 75 degrees C. Lugs for conductors 1/0 AWG and larger shall be two-hole lugs with NEMA spacing. The lugs shall be of closed end construction to exclude moisture migration into the cable conductor.

J. Space heaters shall be continuously energized as specified.

3.2 TESTS

A. Test for proper rotation prior to connection to the driven equipment.

B. Test the insulation (megger test) of all new motors, 10 hp and above, in accordance with NEMA MG-1. Test voltage shall be 1000 VAC plus twice the rated voltage of the motor.

C. For motors 300 hp and larger, test duration shall be for 10 minutes with resistances tabulated every 15 seconds for the first minute and then every minute for the next ten. The megohm rating at the end of the 10 minutes shall be at least twice as high as the 1-minute reading. Dielectric absorption ratio and polarization index shall be calculated.

D. Perform a rotation test to ensure proper shaft direction.

E. Where a motor is inverter fed, the direction of rotation shall be checked by momentary application of voltage to the motor, to confirm that the phase sequence is the same as the incoming power to the inverter.

F. Measure running current and evaluate relative to load conditions and nameplate full load amperes.

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G. Inspect for unusual mechanical or electrical noise or signs of overheating during initial test run.

H. Monitor motors during startup and commissioning to record operating amps, voltage and operating vibration levels.

I. Submit test report and all recorded field data. Submit copies of the raw data recorded in the field, signed by the person recording the data, and typewritten reports certified by the Contractor. The motors will not be accepted until the reports are submitted and approved.

PART 4 - TABLE OF MOTOR EFFICIENCIES

MOTOR FULL-LOAD EFFICIENCIES

2 POLE (3600 RPM)

4 POLE (1800 RPM)

6 POLE (1200 RPM)

8 POLE (900 RPM)

HP

Min. Efficiency

Min. Efficiency

Min. Efficiency

Min. Efficiency

1.0 72.0 80.0 77.0 70.0

1.5 80.0 81.5 82.5 74.0

2.0 81.5 81.5 84.0 80.0

3.0 82.5 85.5 85.5 81.5

5.0 85.5 85.5 85.5 82.5

7.5 87.5 87.5 87.5 82.5

10.0 88.5 87.5 87.5 86.5

15.0 89.5 89.5 88.5 87.5

20.0 88.5 89.5 88.5 87.5

25.0 89.5 91.0 90.2 87.5

30.0 89.5 91.0 90.2 89.5

40.0 90.2 91.7 91.7 89.5

50.0 91.0 91.7 91.7 90.2

60.0 91.7 92.4 92.4 90.2

75.0 91.7 93.0 92.4 91.7

100.0 92.4 93.6 93.0 91.7

125.0 93.6 93.6 93.0 92.4

150.0 93.6 94.1 94.1 92.4

200.0 94.1 94.1 94.1 93.0

250.0 94.5 94.1 94.1 93.6

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300.0 994.5 94.5 94.1 --

350.0 94.5 94.5 94.1 --

400.0 94.5 94.5 --

450.0 94.5 94.5 --

500.0 94.5 95.0 --

END OF SECTION

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LOW VOLTAGE AC SURGE PROTECTIVE DEVICES (SPDS) Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16196 LOW VOLTAGE AC SURGE PROTECTIVE DEVICES (SPDS).DOCX

SECTION 16196 LOW VOLTAGE AC SURGE PROTECTIVE DEVICES (SPDs)

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. This Section of the Specifications describes the requirements for low voltage AC surge protective devices (SPDs 1Kv and less), to be furnished under other Sections of the Specifications as listed in the Related Work paragraph of this Section.

B. All equipment described herein shall be submitted, and factory installed, as an integral part of equipment specified elsewhere in these Specifications.

1.2 SUBMITTALS

A. Submittals for equipment specified herein shall be made as a part of equipment furnished under other Sections. Individual submittals for equipment specified herein will not be accepted and will be returned unreviewed.

B. Submit catalog data for all items supplied from this specification Section as applicable. Submittal shall include catalog data, functions, ratings, inputs, outputs, displays, etc., sufficient to confirm that the SPD provides every specified requirement. Any options or exceptions shall be clearly indicated, with the reason for such deviations. Acceptance of any deviation will be at the sole discretion of the Owner/Engineer. Shop drawings, not so checked and noted, will be returned unreviewed.

C. The submittals shall include: 1. Dimensional drawing of each SPD type. 2. UL 1449 Third Edition Listing, Standard for Safety, Surge Protective Devices,

documentation. Provide verification that the SPD complies with the required ANSI/UL 1449 3rd Edition listing by Underwriters Laboratories (UL) or other Nationally Recognized Testing Laboratory (NRTL).

3. UL 1283 Listing, Electromagnetic Interference Filters, documentation. 4. ANSI/IEEE C6241 and C6245, Category C3 (20kV-1.2/50, 10kA-8/20µs waveform)

clamping voltage test results.

D. Operation and Maintenance Manuals. 1. Operation and Maintenance manuals shall include the following information:

a. Manufacturer’s contact address and telephone number for parts and service. b. Instruction books and/or leaflets c. Recommended renewal parts list d. Record Documents for the information required by the Submittals above.


A. The equipment in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. UL 1449 Third Edition – Surge Protective Devices 2. UL 1283 Electromagnetic Interference Filters 3. ANSI/IEEE C62.41.2-2002 – IEEE Recommended Practice on Characterization of Surge

Voltages in Low Voltage AC Power Circuits 4. ANSI/IEEE C62.45-2002 – IEEE Recommended Practice on Surge Testing for

Equipment Connected to Low-Voltage AC Power Circuits. 5. NEC Article 285 - Surge Protective Devices 6. NEMA/ISCI – 109 Transient Overvoltage Withstand Test 7. IEEE Std. 472/ANSI C37.90A Surge Withstand Capability Tests 8. IEC 255.4 Surge Withstand Capability Tests

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B. All SPDs and their installation shall comply with the requirements of the National Electric Code and Underwriters Laboratories (UL) where applicable.



A. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

B. The manufacturer of the SPD shall be the same as the manufacturer of the service entrance and distribution equipment in which the devices are installed and shipped. The protected electrical equipment, after installation of the SPD, shall be fully tested and certified to the following UL standards: 1. UL 67 - Panelboards. 2. UL 845 - Motor Control Centers. 3. UL 891 - Switchboards. 4. UL 1558 - Low Voltage Switchgear.

C. For the equipment specified herein, the manufacturer shall be ISO 9001 or 9002 certified.

1.5 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 10 years from date of acceptance of the equipment containing the items specified in this Section. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Manufacturer at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable (Type 1 and Type 2): 1. Cutler Hammer. 2. General Electric Co. 3. Square D 4. Allen Bradley 5. No Equal

B. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable (Type 3): 1. Edco SLAC Series 2. Phoenix Contact 3. Brick Wall Model PWOM20 4. No Equal

2.2 SERVICE ENTRANCE AND DISTRIBUTION EQUIPMENT

A. General 1. All SPDs shall be internal to the equipment being protected. Externally housed SPDs will

not be acceptable.

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2. All SPDs shall be marked with a short-circuit current rating, and shall meet or exceed the available fault current at the connection point.

3. UL 1449 Usage Classifications. a. Type 1 – Permanently connected SPDs intended for installation between the

secondary of the service transformer and the line side of the service equipment overcurrent device, and intended to be installed without an external overcurrent protective device.

b. Type 2 – Permanently connected SPDs intended for installation on the load side of service equipment overcurrent device; including SPDs located at the branch panel.

c. Type 3 – Point of utilization SPDs, installed at a minimum conductor length of 10 meters (30 feet) from the electrical service panel to the point of utilization, for example cord connected, direct plug-in, receptacle type and SPDs installed at the utilization equipment being protected. The distance (10 meters) is exclusive of conductors provided with or used to attach SPDs.

4. Construction of Type 1 and Type 2. a. Fully Integrated Component Design: All of the SPD’s components and diagnostics


b. Overcurrent Protection: The unit shall contain thermally protected MOVs. The thermally protected MOVs shall have a thermal protection element packaged together with the MOV in order to achieve overcurrent protection of the MOV. The thermal protection element shall disconnect the MOV(s) from the system in a fail-safe manner should a condition occur that would cause them to enter a thermal runaway condition.

c. Maintenance Free Design: The SPD shall be maintenance free and shall not require any user intervention throughout its life. SPDs containing items such as replaceable modules, replaceable fuses, or replaceable batteries are not acceptable. SPDs requiring any maintenance of any sort such as periodic tightening of connections are not acceptable.

d. Balanced Suppression Platform: The surge current shall be equally distributed to all MOV components to ensure equal stressing and maximum performance. The surge suppression platform must provide equal impedance paths to each matched MOV. Designs incorporating replaceable SPD modules are not acceptable.

e. Electrical Noise Filter: Each unit shall include a high-performance EMI/RFI noise rejection filter. Noise attenuation for electric line noise shall be up to 50 dB from 10 kHz to 100 MHz using the MIL-STD-220A insertion loss test method.

f. Internal Connections: No plug-in component modules or printed circuit boards shall be used as surge current conductors. All internal components shall be soldered, hardwired with connections utilizing low impedance conductors.

g. Power and ground connections shall be prewired within the protected equipment. h. Local Monitoring: Visible indication of proper SPD connection and operation shall

be provided. The indicator lights shall indicate which phase as well as which module is fully operable. The status of each SPD module shall be monitored on the front cover of the enclosure as well as on the module. A push-to-test button shall be provided to test each phase indicator. Push-to-test button shall activate a state change of dry contacts for testing purposes.

i. Surge Counter: The SPD shall indicate user how many surges have occurred at the location. The surge counter shall trigger each time a surge event with a peak current magnitude of a minimum of 50 ± 20A occurs. A reset pushbutton shall also be standard, allowing the surge counter to be zeroed. The reset button shall contain a mechanism to prevent accidental resetting of the counter via a single, short-duration button press. To prevent accidental resetting, the surge counter reset button shall be depressed for a minimum of 2 seconds in order to clear the

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surge count total. The ongoing surge count shall be stored in non-volatile memory or UPS backup.

j. Remote Monitoring: For remote monitoring, the SPDs shall provide the same discrete and analog signal and control functions as specified for local monitoring and the surge counter, to a terminal strip for outgoing connection to a PLC as shown on the Drawings. The functions shall be converted as specified for interface to the monitored equipment.

k. The voltage surge suppression system shall incorporate thermally protected metal-oxide varistors (MOVs) as the core surge suppression component for the service entrance and all other distribution levels. The system shall not utilize silicon avalanche diodes, selenium cells, air gaps, or other components that may crowbar the system voltage leading to system upset or create any environmental hazards.

l. SPD shall be Listed in accordance with UL 1449 Third Edition and UL 1283, Electromagnetic Interference Filters.

m. Integrated surge protective devices (SPD) shall be Component Recognized in accordance with UL 1449 Third Edition, Section 37.3.2 and 37.4 at the standard’s highest short circuit current rating (SCCR) of 200 kA, including intermediate level of fault current testing.

n. SPD shall be tested with the ANSI/IEEE Category C High exposure waveform (20kV-1.2/50µs, 10kA-8/20µs).

o. SPD shall provide suppression for all modes of protection: L-N, L-G, and N-G in WYE systems (7 Mode).

5. Construction of Type 3. a. Fully Integrated Component Design: All of the SPD’s components and diagnostics


b. Maintenance Free Design: The SPD shall be maintenance free and shall not require any user intervention throughout its life. SPDs containing items such as replaceable modules, replaceable fuses, or replaceable batteries are not acceptable. SPDs requiring any maintenance of any sort such as periodic tightening of connections are not acceptable.

c. Electrical Noise Filter: Each unit shall include a high-performance EMI/RFI noise rejection filter. Noise attenuation for electric line noise shall be up to 50 dB from 10 kHz to 100 MHz using the MIL-STD-220A insertion loss test method.

d. Internal Connections: No plug-in component modules or printed circuit boards shall be used as surge current conductors. All internal components shall be soldered, hardwired with connections utilizing low impedance conductors.

e. Power and ground connections shall be prewired within the protected equipment. f. Local Monitoring: Visible indication of proper SPD connection and operation shall

be provided. The indicator light shall indicate that the module is fully operable. The status of each SPD module shall be monitored on the front cover of the module.

g. SPD shall be Listed in accordance with UL 1449 Third Edition and UL 1283, Electromagnetic Interference Filters.

h. SPD shall be tested with the ANSI/IEEE Category C High exposure waveform (20kV-1.2/50µs, 10kA-8/20µs).

B. Applications. 1. Service Entrance Rated Equipment (Type 1).

a. This applies to switchgear, switchboards, panelboards, motor control centers, and other devices installed as service entrance equipment where the SPD is to be permanently connected between the secondary of the service transformer and the line side of the service equipment overcurrent device.

b. Service entrance located SPDs shall be tested and demonstrate suitability for application within ANSI/IEEE C62.41 Category C environments.

c. The SPD shall be of the same manufacturer as the equipment

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d. The SPD shall be factory installed inside the equipment, at the assembly point, by the original equipment manufacturer

e. Locate the SPD on the load side of the main disconnect device, as close as possible to the phase conductors and the ground/neutral bars.

f. The SPD shall be connected through a UL approved disconnecting means. The disconnect shall be located in immediate proximity to the SPD. Connection shall be made via bus, conductors, or other connections originating in the SPD and shall be kept as short as possible.

g. The SPD shall be integral to the equipment as a factory standardized design. h. All monitoring and diagnostic features shall be visible from the front of the

equipment. 2. Distribution Equipment Applications (Type 2).

a. This applies to switchgear, switchboards, panelboards, motor control centers, and other non-service entrance equipment where the SPD is to be permanently connected on the load side of the equipment overcurrent device.

b. The SPD shall be of the same manufacturer as the equipment. c. The SPD shall be included and mounted within the equipment by the manufacturer. d. The manufacturer shall size and provide the overcurrent and disconnecting means

for the SPD. e. The SPD units shall be tested and demonstrate suitability for application within

ANSI/IEEE C62.41 Category B environments. f. The SPD shall be located within the panelboard, unless otherwise shown on the

Drawings. SPDs shall be installed immediately following the load side of the main breaker. SPDs installed in main lug only panelboards shall be installed immediately following the incoming main lugs.

g. The SPD shall not limit the use of through-feed lugs, sub-feed lugs, and sub-feed breaker options.

h. All monitoring and diagnostic features shall be visible from the front of the equipment.

3. Individual Control Panel and Related Equipment Protection (Type 3). a. Locate the SPD on the load side of the ground and neutral connections. b. The SPD shall be connected through a disconnect circuit breaker or fuse as shown

on the drawings. The disconnecting means shall be located in immediate proximity to the SPD. Connection shall be made via bus, conductors, or other connections originating in the SPD and shall be kept as short as possible.

c. All monitoring and diagnostic features shall be visible from the front of the equipment.

4. Mechanical Equipment Manufacturer’s Provided Control Panels (MEMs) and Electrical Manufacturer’s Provided Control Panels (OEMs) Applications (Type 1, Type 2, and Type 3) a. Where any such panel is installed as service entrance equipment, a Type 1 SPD

shall be installed. 1) The same requirements for other service entrance equipment listed above

apply to this application except for the requirement that the Type 1 SPD shall not be required to be of the same manufacturer as the panel.

b. Where any such panel is installed as non-service entrance equipment, but within 50’ of wire length of the incoming power line when that line is overhead. 1) The same requirements for other non-service entrance equipment listed

above apply to this application except for the requirement that the Type 2 SPD shall not be required to be of the same manufacturer as the panel.

2) Where a Type 1 SPD is installed, a Type 2 SPD is not required on the same panel unless otherwise specifically shown on the drawings.

c. Where any such panel includes a PLC, a Type 3 SPD shall be installed. 1) The same requirements for other individual control panel and related

equipment listed above apply to this application.

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2) The SPD shall be integral to the MEM or OEM panel, as a factory standardized design.

C. Ratings 1. Unit Operating Voltage: Refer to drawings for operating voltage and unit configuration. 2. SPD shall be designed to withstand a maximum continuous operating voltage (MCOV)

of not less than 115% of nominal RMS voltage. 3. Minimum surge current rating shall be 240 kA per phase (120 kA per mode) for service

entrance and 120 kA per phase (60 kA per mode) for distribution applications. 4. UL 1449 clamping voltage must not exceed the following: Voltage Protection Rating

(VPR)

Voltage L-N L-G N-G

240/120 1200/800V 800V 800V

208Y/120 800V 800V 800V

480Y.277 1200V 1200V 1200V

600Y/347 1500V 1500V 1500V

5. Pulse life test: Capable of protecting against and surviving 5000 ANSI/IEEE Category C

High transients without failure or degradation of clamping voltage by more than 10%. 6. Minimum UL 1449 3rd edition withstand Nominal Discharge Current (In) rating to be 20kA

per mode

2.3 ACCESSORIES

A. Furnish nameplates for each device as indicated on drawings. Color schemes shall be as indicated on Drawings.

PART 3 - EXECUTION

3.1 INSTALLATION

A. All equipment specified herein shall be factory installed, field adjusted, tested and cleaned as an integral part of equipment specified elsewhere in the individual equipment Specification.

B. Types 1 and 2 shall be grounded and bonded as a part of the individual equipment as specified in the individual equipment Section. Type 3 shall be grounded and bonded in accordance with the SPD manufacturer’s instructions.

END OF SECTION

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LOW VOLTAGE ENCLOSED CIRCUIT BREAKERS AND DISCONNECT SWITCHES Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16475 LOW VOLTAGE ENCLOSED CIRCUIT BREAKERS AND DISCONNECT SWITCHES.DOCX

SECTION 16475 LOW VOLTAGE ENCLOSED CIRCUIT BREAKERS AND DISCONNECT SWITCHES

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The Contractor shall furnish and install low voltage enclosed circuit breakers and disconnect switches, together with appurtenances, complete and operable, as specified herein and as shown on the Contract Drawings.

B. All equipment specified in this Section of the Specifications shall be the product of one manufacturer and shall be factory constructed and assembled by that manufacturer.

C. The Bid Price shall be in complete compliance with the Contact Documents. Any exception shall be included in the bid with a detailed explanation that clearly indicates the paragraph of this Specification and / or the item in the Drawings to which the exception applies. The Contractor shall explain in detail the reasons for the exception. The inclusion of an exception and its explanation as specified shall not constitute any obligation on the part of the Engineer / Owner to accept the Bid Price with the exception.

D. This Specification shall have precedence over any conflict in the bidders submittals and / or descriptive information and the Contract Documents unless an exception is made at the time of bidding as specified herein, and the bid price is accepted with the bidder’s exception by the Engineer / Owner.

E. The Contractor shall provide all tools, equipment, supplies, and shall perform all labor required to install the equipment specified in the Contract Documents in order to install, test, and place into satisfactory operation in the time specified for completion in the Contract Documents. Failure of any of the Contractors sub-contractors or suppliers to perform the work as specified shall not constitute an acceptable reason for the Owner to grant any change in the Contract Price or additions to the Contract Time.

1.2 RELATED WORK


B. Section 16045 Electrical Support Hardware

C. Section 16105 Power System Study

D. Process Equipment Division 11 Specifications

E. Instrumentation Equipment Division 17 Specifications

F. Mechanical Equipment Division 15 Specifications

G. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

H. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different

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1.3 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of Division 1, Section 16000 and as specified herein.

B. Submittals for equipment and materials, furnished under this Section of the Specifications, will not be accepted prior to approval of the Power System Study specified under Section 16105. Submittals made prior to such approval will be returned without review.

C. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will also be returned without review. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

D. The original equipment manufacturer shall create all equipment shop drawings, including all wiring diagrams, in the manufacturer’s Engineering department. All equipment shop drawings shall bear the original equipment manufacturers logo, drawing file numbers, and shall be maintained on file in the original equipment manufacturer’s archive file system. Photocopies of the Engineer’s ladder schematics are unacceptable as shop drawings.

E. Submit to the Owner/Engineer, shop drawings and product data, for the following: 1. Product data sheets and catalog numbers for overcurrent protective trip devices on circuit

breakers and switches, relaying, meters, pilot lights, etc. The manufacturer’s name shall be clearly visible on the each cut sheet submitted. List all options, trip adjustments and accessories furnished specifically for this project.

2. Provide control systems engineering to produce custom unit elementary drawings showing inter-wiring and interlocking between components and to remotely mounted devices. Include and identify all connecting equipment and remote devices on the schematics. The notation “Remote Device” will not be acceptable. Show wire and terminal numbers. Indicate special identifications for electrical devices per the Drawings.

3. Provide plan and elevation drawings of each controller or enclosure, with dimensions, exterior and interior views, showing component layouts, controls, terminal blocks, etc..

4. Schematic diagram 5. Nameplate schedule 6. UL Listing of the completed assembly. 7. Component list with detailed component information, including original manufacturer’s

part number. 8. Conduit entry/exit locations 9. Assembly ratings including:

a. Short-circuit rating b. Voltage c. Continuous current

10. Major component ratings including: a. Voltage b. Continuous current c. Interrupting ratings

11. Number and size of cables per phase, neutral if present, ground and all cable terminal sizes.

12. Instruction and renewal parts books.

F. Factory Tests. Submittals shall be made for factory tests specified herein.


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H. Operation and Maintenance Manuals. 1. Operation and maintenance manuals shall include the following information:

a. Manufacturer’s contact address and telephone number for parts and service. b. Instruction books and/or leaflets c. Recommended renewal parts list d. Record Documents for the information required by the Submittals paragraph

above.

I. The manufacturer shall submit for approval, a training agenda for all training specified herein. Training agenda shall not be submitted until final approval of the Operation and Maintenance Manual.

J. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA Standard AB1 – Molded Case Circuit Breakers, Molded Case Switches and

Circuit Breaker Enclosures 2. NFPA 70 – National Electrical Code (NEC) 3. NFPA 70E – Standard For Electrical Safety in the Workplace 4. IEEE 242 – Protection and Coordination of Industrial and Commercial Power Systems 5. IEEE 399 – Power Systems Analysis 6. UL 489 – Molded Case Circuit Breakers and Circuit Breaker Enclosures 7. UL 1066 – Low Voltage AC and DC Power Circuit Breakers Used in Enclosures.



A. The manufacturer of this equipment shall have produced similar equipment for a minimum period of ten (10) years. When requested by the Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

B. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly. All assemblies shall be of the same manufacturer. Equipment that is manufactured by a third party and “brand labeled” shall not be acceptable.

C. All components and material shall be new and of the latest field proven design and in current production. Obsolete components or components scheduled for immediate discontinuation shall not be used.

D. For the equipment specified herein, the manufacturer shall be ISO 9001 2000 certified.

E. Equipment submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.


A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner/Engineer upon delivery of the equipment, an approved

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copy of all such submittals. Delivery of incomplete constructed equipment, or equipment which failed any factory tests, will not be permitted.,

B. Equipment shall be handled and stored in accordance with manufacturer's instructions. Two (2) copies of these instructions shall be included with the equipment at time of shipment, and shall be made available to the Contractor and Owner. The instructions shall include detailed assembly instructions including but not limited to wiring interconnection diagrams, rigging for lifting, skidding, jacking and moving using rolling equipment to place the equipment, bolt torqueing requirements for bus and all other components which require the installation of bolted connections, and instructions for storing the equipment prior to energizing.



1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment or components shall be performed by the Contractor at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Eaton 2. General Electric Co. 3. Schneider Electric / Square D 4. No Equal


C. All equipment furnished under this Section shall be of the same manufacturer.

2.2 RATINGS

A. The service voltage, shall be as shown on the Drawings. The overall short circuit withstand and interrupting rating of the equipment and devices shall be equal to or greater than the overall short circuit withstand and interrupting rating of the feeder device immediately upstream of the circuit breaker or switch. Systems employing series connected ratings for main and feeder devices shall not be used.

B. Circuit breakers, safety switches and associated devices shall be designed for continuous operation at rated current in a 40 degree C ambient temperature.

C. Furnish heavy duty Mill rated devices.

D. For additional ratings and construction notes, refer to the Drawings.

2.3 CONSTRUCTION

A. General

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1. Refer to Drawings for: actual layout and location of equipment and components; current ratings of devices, components; protective relays, voltage ratings of devices, components and assemblies; and other required details.

2. Furnish lugs for incoming wiring, sizes as shown on the Drawings. Allow adequate clearance for bending and terminating of cable size and type specified, Lugs for # 12 AWG up to # 6 AWG shall be ring terminals. Conductors # 4 AWG and larger shall be two-hole long barrel lugs with NEMA spacing. All lugs shall be the closed end construction to exclude moisture migration into the cable conductor. See also Section 16120 Wires and Cables (1000 Volt Maximum) for additional requirements.

3. Built in control stations and indicating lights shall be furnished where shown on the Drawings.

4. Furnish nameplates for each device as indicated in Drawings. Nameplates shall be engraved, laminated impact acrylic, matte finish, not less than 1/16-in thick by 3/4-in by 2-1/2-in, Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures except for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”, or equal. Prior to installing the nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residue has been removed. Epoxy adhesive or foam tape is not acceptable.

B. Enclosures 1. General

a. Provide 316 SS hardware for all enclosures. b. All enclosure doors shall have bonding studs. The enclosure interior shall have a

bonding stud. c. Enclosures shall not have holes or knockouts for conduit entry. d. All panels installed outdoors shall have a factory applied, suitable primer and final

coat of weatherproof white paint. e. All enclosures shall be provisioned with hardware for a padlock. f. All enclosures shall have integral welded mounting lugs. g. See Section 16110 Raceways, Boxes and Fittings for additional requirements.

2. NEMA 7/4X a. Class 1, Division 1, Groups A, B, C, and D, or as defined in NFPA 70). Boxes shall

be constructed as follows: 1) Copper free cast aluminum body and cover 2) Stainless steel hinges 3) Watertight neoprene gasket 4) Stainless steel cover bolts 5) All penetrations shall be factory drilled and tapped.

3. NON METALLIC a. Chemical Rooms. NEMA 4X constructed as follows:

1) PVC or Fiberglass reinforced polyester body and door. 2) UV inhibitors 3) Luggage type quick release latches 4) Foam-in-place gasketed doors

4. ALUMINUM a. NEMA 4X Aluminum

1) Type 5052 aluminum, body and door 2) Stainless steel hinge 3) Foam in-place gasket 4) Single point quarter turn latches

5. NEMA 12 a. NEMA 12 Steel

1) Mild steel body and door 2) Stainless steel hinges 3) Foam in-place gasket 4) Single point quarter turn latches

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6. NEMA 4X Stainless Steel where not otherwise Defined a. Where an enclosure is not otherwise defined or shown on the Drawing

1) NEMA 4X Stainless Steel 2) Type 316 stainless steel, body and door 3) Stainless steel hinge 4) Foam in-place gasket 5) Single point quarter turn latches

7. NEMA 1 or NEMA 1A boxes shall not be used. 8. Malleable iron boxes shall not be used. 9. Provide a flange mounted, or through the door, disconnect operating handle with

mechanical interlock having a bypass that will allow the enclosure door to open only when the circuit breaker or switch is in the OFF position. The circuit breaker or switch shall have the capability of being bypassed after the door has been opened.

C. Internal Wiring 1. Wiring: Stranded tinned copper, minimum size No. 14 AWG, with 600 Volt, 90-degree

C, flame retardant, Type 600-volt insulation, NEMA Class II, Type B wiring. Line side power wiring shall be sized for the full rating or frame size of the connected device.

2. All wiring shall be tagged and coded with an identification number as shown on the Drawings. Coding shall be typed on a heat shrinkable tube applied to each end showing origination and destination of each wire. The marking shall be permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal. Wire tags shall be machine-printed. Wire tags relying on adhesives of any type are unacceptable.

3. All wiring shall be neatly bundled with tie wraps and supported to wire way supports. Control wiring shall be bundled separately from power wiring. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring.

D. Field Installed Internal Wiring 1. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie

wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring. Wiring shall not be supported using adhesive supports. Adhesive wire supports are unacceptable, and if installed shall be removed and replaced with a non-adhesive support with no increase in Contract Price or Time.

2. All field wiring shall be tagged and coded with an identification number. Coding shall be typed on a heat shrinkable tube applied to each end of the wire. The marking shall be a permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal. Wire tags shall be machine-printed. Wire tags relying on adhesives of any type are unacceptable.

3. In general, all conduit entering or leaving equipment shall be stubbed up into the bottom of the enclosure directly below the area in which the conductors are to be terminated, or from the top if shown on the Drawings and not located in a wet, damp or any process area. Conduits shall not enter the side unless approved in writing by the Owner/Engineer.

2.4 CIRCUIT BREAKERS

A. Molded Case Circuit Breakers (MCCB’s) 1. Unless otherwise shown on the Drawings, circuit breakers 225 ampere frame rating and

larger, shall be molded case (MCCB), 3 Pole, 600 Volt, fixed type, with stored energy closing mechanism. Breakers shall be manually operated unless indicated as electrically operated (EO) on the Drawings. Trip device shall be solid state with adjustable long time pickup, and delay; adjustable short time pickup and delay; short time i2t switch.

2. Unless otherwise shown on the Drawings, circuit breakers less than 225 ampere frame rating shall be molded case, 3 Pole, 600 Volt, fixed type, manually operated with stored energy closing mechanism. Circuit breakers shall have inverse time and instantaneous tripping characteristics.

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2.5 DISCONNECT SWITCHES

A. Disconnect switches shall be heavy duty, quick make, quick break, visible blades, 600 Volt, 3 Pole with full cover interlock, interlock defeat and flange mounted operating handle.

2.6 FUSED DISCONNECT SWITCHES

A. Fused disconnect switches shall be heavy duty, quick make, quick break, visible blades, 600 Volt, 3 Pole with full cover interlock, interlock defeat and flange mounted operating handle.

B. Fuses shall be rejection type, 600 Volts, 200,000 A.I.C., dual element, time delay, Bussman Fusetron, Class RK 5 or equal.

2.7 SPARE PARTS

A. Provide the following spare parts: 1. 3 – Fuses of each type used.

B. Spare parts shall be boxed or packaged for long term storage and clearly identified on the exterior of package. Identify each item with manufacturers name, description and part number

2.8 FACTORY TESTING

A. The circuit breakers and disconnects shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer’s routine shop tests and any other additional operational test to insure the workability and reliable operation of the equipment.

B. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards, and shall be subject to the Owner/Engineer’s approval.

PART 3 - EXECUTION


A. Installer shall be specialized in installing low voltage circuit breakers and disconnect switches with minimum 5 years documented experience. Experience documentation shall be submitted for approval prior to beginning work on this project.

3.2 EXAMINATION



C. Verify field measurements are as instructed by manufacturer.

3.3 INSTALLATION


B. Install required safety labels.

C. Conduit entry into the top of any NEMA 4/4X rated enclosure in any outdoor, damp, wet or process area is strictly prohibited. Any enclosure entered from the top will be removed, the conduit and conductors re-routed, or conductors replaced if too short. No increase in Contract Price or Contract Time will be allowed.

D. All enclosures shall have integral welded mounting lugs. Bolt-on lugs are unacceptable, and enclosures with lugs so mounted will be rejected and if mounted shall be removed and replaced at the Contractor’s expense. No change in Contract Price or Time will be allowed. Drilling

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through the back of enclosures to mount is prohibited, and any enclosure so mounted will be rejected and shall be removed and replaced at the Contractor’s expense. No change in Contract Price or Time will be allowed.




3.5 FIELD ADJUSTING

A. Adjust all circuit breakers, switches, access doors, operating handles for free mechanical and electrical operation as described in manufacturer's instructions.

B. The Power Monitoring and Protective Devices shall be set in the field by a qualified representative of the manufacturer, retained by the Contractor, in accordance with settings designated in a coordinated study of the system as required in Section 16105 Power System Study. All such settings, including the application of arc flash labels, shall have been made and Approved by the Owner/Engineer, prior to energizing of the equipment.

3.6 FIELD TESTING

A. Perform all electrical field tests recommended by the manufacturer. Disconnect all connections to solid-state equipment prior to testing.

B. Megger and record phase to phase and phase to ground insulation resistance. Megger, for 1 minute, at minimum voltage of 1000 VDC. Measured Insulation resistance shall be at least 100 megohms. In no case shall the manufacturer’s maximum test voltages be exceeded.

C. Test the ground fault protection system using a high current injection method.

D. Test the rating plug for correct rating.

3.7 CLEANING




END OF SECTION

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LOW VOLTAGE MOTOR CONTROL CENTERS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16480 LOW VOLTAGE MOTOR CONTROL CENTERS.DOCX

SECTION 16480 LOW VOLTAGE MOTOR CONTROL CENTERS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The Contractor shall furnish and install assemblies of low voltage motor control centers (MCCs), in existing MCCs 7, 8 and 9 as shown on the drawings and as specified here in. The Contractor shall provide all required appurtenances, complete and operable, as specified herein and as shown on the Contract Drawings.

B. New variable frequency drives, SPDs, FVNR starters, circuit breakers, bucket doors, operating handles, modifications to bus as required, control and power conductors, door mounted and internal control switches, speed control potentiometers and door mounted push-to-test lights shall be factory-issues components installed by the motor control center manufacturer’s field services personnel as shown on the Drawings, as specified and as required for a complete and operable system.

C. Motor Control Centers 7 and 8 are manufactured by General Electric Corporation, and modifications to these MCCs shall be done by General Electric Field Services, and use only GE manufactured or approved components. Motor Control Centers shall continue to meet all NEMA and UL standards and shall remain to be UL listed when the work is complete.

D. Motor Control Centers 9 was manufactured by Square D Corporation, and modifications to these MCCs shall be done by Square D (Schneider Electric) Field Services, and use only Square D manufactured or approved components. Motor Control Centers shall continue to meet all NEMA and UL standards and shall remain to be UL listed when the work is complete.

1.2 RELATED WORK





E. Section 16196 Low Voltage AC Surge Protective Devices (SPDs)





J. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different

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1.3 SUBMITTALS


B. Provide systems engineering to produce coordination curves, showing coordination between existing and breakers and/or fuses submitted, such that protective device coordination is accomplished. Such curves and settings shall be included as a part of these submittals.

C. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will also be returned unreviewed.

D. MCCs 7, 8 and 9 are specified and shown to be modified as a part of this Contract. The original MCC equipment manufacturer shall modify the original shop drawings and shall create a complete set of new MCC shop drawings showing all changes made under this Contract. The modified shop drawings shall include all wiring diagrams and physical / structural changes, and shall be done in the manufacturer’s engineering department. All MCC shop drawings shall bear the original equipment manufacturers MCC logo, drawing file numbers, and shall be maintained on file in the manufacturer’s MCC archive file system. Include an updated complete bill of material and cut sheets of all components, both new and existing, such that one document shows all items in the MCCs as they are after modification. Photocopies of the Engineer’s ladder schematics are unacceptable as shop drawings.

E. Submit to the Owner/Engineer, shop drawings and product data, for the following: 1. Equipment outline drawings showing elevation and plan views, dimensions, weight,

shipping splits and metering layouts of each MCC as modified. Indicate all options, special features, ratings and deviations from the Specifications.

2. Conduit entrance drawings, including floor penetrations. 3. Bus arrangement drawings. 4. Unit summary tables showing detailed equipment description and nameplate data for

each compartment. 5. Product data sheets and catalog numbers for overcurrent protective devices, motor

starters, control relays, control stations, meters, pilot lights, etc. showing all modifications and existing unmodified items. List all options, trip adjustments and accessories furnished specifically for this project. Clearly mark each sheet to indicate which items apply and/or those items that do not apply, as well as what items are new and a part of the required modifications and what items were originally provided and remain unmodified. The submittal is to provide the Owner with one document which is complete showing all MCC components as if they were originally furnished as modified.

6. Provide control systems engineering to produce custom unit elementary drawings showing inter-wiring and interlocking between units and to remotely mounted devices. Show wire and terminal numbers. Indicate special identifications for electrical devices per the Drawings.

7. Master drawing index 8. Front view elevation 9. Floor plan 10. Top view 11. Single line 12. Schematic diagram, including manufacturer’s selections of component ratings, and CT

and PT ratios. 13. Nameplate schedule 14. UL Listing of the completed assembly.

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15. Component list with detailed component information, including original manufacturer’s part number.

16. Conduit entry/exit locations 17. Assembly ratings including:



19. Descriptive bulletins 20. Product data sheets. 21. Number and size of cables per phase, neutral if present, ground and all cable terminal

sizes. 22. Floor mat 23. Instruction and renewal parts books. 24. Itemized list of spare parts furnished specifically for this project, including quantities,

description and part numbers.

F. Harmonic distortion calculations for Variable Frequency Drives (VFDs).

G. Factory Tests. Submittals shall be made for factory tests specified herein.

H. Field Test Reports. Submittals shall be made for field tests specified herein.

I. Operation and Maintenance Manuals. 1. Operation and maintenance manuals shall include the following information:


above.

J. The manufacturer shall submit for approval, a training agenda for all training specified herein. Training agenda shall not be submitted until final approval of the Operation and Maintenance Manual.


A. The low voltage motor control centers and all components in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA Standard ICS 2 – 2000 Industrial Control and Systems 2. UL 845 – Electric Motor Control Centers 3. NEMA Standard SG-3 – Low Voltage Power Circuit Breakers 4. NFPA 70 – National Electrical Code (NEC) 5. NFPA 70E – Standard For Electrical Safety in the Workplace 6. ANSI IEEE Standard C62.41-1991 Surge Withstand Capacity 7. CSA 22.2, No. 14 & 66 CSA requirements for power electronics 8. FCC Part 15, Sub Part J, Class A RFI/EMI emission standards 9. ANSI IEEE Standard 519-1992 Harmonic limits 10. UL 508C [UL requirements for power conversion equipment


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B. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly. All assemblies shall be of the same manufacturer. Equipment that is manufactured by a third party and “brand labeled” shall not be acceptable.


D. Equipment submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.

E. For the equipment specified herein, the manufacturer shall be ISO 9001 2000 certified.



B. Equipment shall be handled and stored in accordance with manufacturer's instructions. Two (2) copies of these instructions shall be included with the equipment at time of shipment, and shall be made available to the Contractor and Owner/Engineer.

C. Shipping groups shall be designed to be shipped by truck, rail, or ship. Indoor groups shall be bolted to skids. Breakers and accessories shall be packaged and shipped separately.

D. Equipment shall be equipped to be handled by crane. Where cranes are not available, equipment shall be suitable for skidding in place on rollers using jacks to raise and lower the groups.

E. Equipment shall be installed in its permanent finished location shown on the Drawings within seven (7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7) calendar days, the equipment shall not be delivered to the site, but stored offsite, at the Contractor’s expense, until such time that the site is ready for permanent installation of the equipment.

F. Where space heaters are provided in equipment, provide temporary electrical power and operate space heaters during jobsite storage, and after equipment is installed in permanent location, until equipment is placed in service.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 2 years, except for variable frequency drives which shall be for 3 years, all from date of final acceptance of the equipment. Within such period of warranty, the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Manufacturer, at no expense to the Owner.

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PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. General Electric Co. (for MCCs 7 and 8 only – no exception or substitution are

acceptable) 2. Square D (for MCC 9 only – no exception or substitution are acceptable)


2.2 RATINGS

A. The service voltage, overall short circuit withstand and interrupting rating of the equipment and devices shall be as shown on the Drawings. Main and feeder circuit protective devices shall be fully rated for the specified short circuit duty. Systems employing series connected ratings for main and feeder devices shall not be used. Motor starter units shall be tested and UL labeled for the specified short circuit duty in combination with the motor branch circuit protective device.

B. The continuous current rating of the main horizontal bus shall be as shown on the Drawings. Vertical busses shall be sized for the structure load and shall have a minimum rating of 300 Amps.

C. Motor control centers, including devices, shall be designed for continuous operation at rated current in a 40-degree C ambient temperature.

D. For additional ratings and construction notes, refer to the Drawings.

2.3 CONSTRUCTION

A. General 1. Refer to Drawings for: actual layout and location of equipment and components; current

ratings of devices, bus bars, components; protective relays, voltage ratings of devices, components and assemblies; and other required details.

2. Control units shall be arranged as shown on the Drawings. 3. Where the equipment contains a variable frequency drive, the equipment manufacturer

shall furnish factory installed, a dedicated Point of Utilization Device (SPD), as specified in Section 16196, Individual Control Panel and Related Equipment Protection (Type 3).

4. Nameplates a. External

1) Furnish nameplates for each device as specified herein and as indicated on the Drawings. All nameplates shall be laminated plastic, black lettering on a white background, attached with stainless steel screws. There shall be a master nameplate that indicates equipment ratings, manufacturer's name, shop order number and general information. Cubicle nameplates shall be mounted on the front face, on the rear panel and inside the assembly, visible when the rear panel is removed.

b. Internal 1) Control components mounted within the assembly, such as fuse blocks,

relays, pushbuttons, switches, etc., shall be suitably marked for identification, corresponding to appropriate designations on manufacturer's wiring diagrams.

c. Special 1) Identification nameplates shall be white with black letters, caution

nameplates shall be yellow with black letters, and warning nameplates shall be red with white letters.

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5. Control Devices and Indicators a. All operating control devices, indicators, and instruments shall be securely

mounted on the panel door. All controls and indicators shall be 30mm, corrosion resistant, NEMA 4X/13, anodized aluminum or reinforced plastic. Booted control devices are not acceptable. Auxiliary contacts shall be provided for remote run indication and indication of each status and alarm condition. Additional controls shall be provided as specified herein and as required by the detailed mechanical and electrical equipment requirements.

b. Indicator lamps shall be LED type. For all control applications, indicator lamps shall incorporate a push-to-test feature. Lens colors shall be as follows: 1) Red for ON, Valve OPEN, and Breaker CLOSED. 2) Green for OFF, Valve CLOSED and Breaker OPEN. 3) Amber for FAIL. 4) Blue for READY 5) White for POWER ON.

c. Mode selector switches (HAND-OFF-AUTO, LOCAL-OFF-REMOTE, etc) shall be as shown on the Drawings. Units shall have the number of positions and contact arrangements, as required. Each switch shall have an extra dry contact for remote monitoring.

d. Pushbuttons, shall be as follows: 1) Red for STOP, Valve OPEN, Breaker OPEN and mushroom Red for

EMERGENCY STOP. 2) Green for START, Valve CLOSE and Breaker CLOSE. 3) Black for RESET.


f. The manufacturer shall not remove, reuse, alter, or replace original equipment nameplates or equipment tags associated with equipment or components supplied by the manufacturer’s suppliers and sub-suppliers.

6. Control and Instrument Power Transformers 7. Control power transformers, encapsulated, shall be provided where shown on the

Drawings. Transformer shall be sized for the entire load, including space heaters, plus 25% spare capacity, and shall be not less than 100VA.

8. Control power transformers shall be 120 volt grounded secondary. Primary side of the transformer shall be fused in both legs. One leg of the transformer secondary shall be solidly grounded while the other leg shall be fused.

B. Enclosures 1. Structures shall be NEMA Type 1A unless noted otherwise on the Drawings. 2. Existing motor control centers consist of a series of metal enclosed, free standing, dead

front vertical sections bolted together to form double wall construction between sections. Individual vertical sections nominally 90 in high, 20 in wide and 20 in deep unless otherwise shown on the Drawings. Vertical sections are mounted on steel channel sills. Bottom channel sills are mounted front and rear of the vertical sections extending the full width of each shipping split. Top of each section has removable plates with lifting angle.

3. Cables shall enter and exit in exposed conduits from the top of the structure, unless existing conduits are found routed to the required locations by the Contractor in the field, and may be, in that cased used by the Contractor.

4. Provide individual, flange formed, pan type door with concealed hinges and quarter turn latches for each device compartment and future space. Doors shall be removable. Door removal shall not be required to withdraw starter units or feeder tap devices.

5. Where an entire section is modified, vertical sections shall contain horizontal wire ways at top and bottom of the structure. The design shall be such to permit a continuous wiring trough from end to end of the entire width of the motor control center. End vertical sections shall have cover plates, which can be easily removed to allow continuation of

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wire ways and horizontal bus extensions for future addition of vertical sections. The vertical section shall also have a continuous vertical raceway extending the full height of the structure and shall intersect with the horizontal raceways. This wire way shall be completely barriered from the bus compartments, the controller compartment, and the adjacent vertical units, and shall have its own separate hinged door.

6. Combination motor control units (Size 5 and smaller), as well as other electrical assemblies, including feeder tap units (225 amp and smaller), shall be provided with appropriately rated stab assemblies for draw out (plug-in) type construction.

7. Plug in provisions shall include a positive guide rail system and stab shrouds to insure alignment of stabs with the vertical bus. The stab shall be designed to increase bus contact pressure during a fault. The stab design shall assure a consistent low-resistance contact with the vertical bus, even after repeated insertions and removals. The unit shall be equipped with a latching mechanism to lock the drawer in an extended or stabbed position for maintenance and testing. Each draw out compartment shall have a separate hinged removable door.

8. Each unit compartment shall be provided with an individual front hinged door. Motor control and feeder units shall be interlocked mechanically with a unit disconnect device to prevent unintentional opening of the door while unit is energized. An interlock between the unit disconnect and the structure shall prevent the removal or reinsertion of the unit when the unit is in the "ON" position. Means shall be provided for releasing the interlock for intentional access and/or application of power. Pad locking arrangements shall permit locking the disconnect device in the "OFF" position.

9. Each modified bucket in the MCC shall be furnished as a completely factory assembled unit.

10. All painted steel work shall be treated with a primer coat and a finish coat, or bonderized and finished with a coat of baked enamel at the factory, such that no field painting will be required except for "touching up" of damaged areas. Color shall be manufacturer’s standard.

11. Furnish documentation with the equipment as follows: Compartments containing motor starters or adjustable frequency drives (VFDs) shall each have an overload heater section table posted inside the door. All control compartments shall have a pocket on the inside of the door with a copy of the appropriate schematic and wiring diagram.

12. The VFDs installed inside the MCC shall be capable of operating at full load in a 40-degree C ambient outside the MCC without having to open the door to the bucket for cooling. If necessary, each cubicle containing a VFD shall have an exhaust fan, thermostatically controlled, for heat dissipation.

C. Construction 1. Provide individual compartments for each removable combination starter and feeder tap

device unit. Each vertical section shall accommodate a maximum of six compartments. Steel barriers shall isolate the top, bottom and sides of each compartment from adjacent units and wire ways. Removable units shall connect to the vertical bus in each section with tin plated, self-aligning, pressure type copper plug connectors. Removable units shall be aligned in the structure on guide rails or shelves and secured with a cam latch mechanism or racking screw.

2. Provide individual, isolated compartments for fixed mounted devices such as circuit breakers, cable lugs, metering, relaying and control devices. Main and bus tie circuit breakers shall be wired directly to the main horizontal bus. All bus connections shall be fully rated.

3. Provide the following features: a. Provision to padlock removable units in a partially withdrawn TEST position, with

the bus stabs disengaged. b. Provision to padlock unit disconnect handles in the OFF position with up to three

padlocks.

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c. Mechanical interlock with bypass to prevent opening unit door with disconnect in the ON position, or moving disconnect to the ON position while the unit door is open.

d. Mechanical split type terminal blocks for disconnecting external control wiring. e. Auxiliary contact on unit disconnect to isolate control power when fed from an

external source. f. Disconnect operating handles and control devices.

D. Wiring 1. Wiring: Stranded tinned copper, minimum size No. 14 AWG, with 600 Volt, 90-degree

C, flame retardant, Type MTW thermoplastic insulation, NEMA Class II, Type B. Line side power wiring shall be sized for the full rating or frame size of the connected device.

2. Identification: Numbered sleeve type wire markers at each termination point, color coding per NEMA standards and the NEC. Foreign voltage control wiring shall be yellow.

3. All control wiring to draw out units shall be run through split type terminal blocks (draw out) which can be split to allow easy unit removal. Motor “T” leads shall bolt directly to starter or overloads and shall not be split type. Terminal blocks shall be of the fully shielded, tubular screw clamp type, resilient collar design to eliminate loose connections. Terminal blocks shall be nickel or tin plated, and have exposed wire numbering corresponding to the connected wires. Terminals shall have a maximum of two wires per terminal.

4. All wiring shall be neatly bundled with ty-raps and supported to wire way supports. Control wiring shall be bundled separately from power wiring. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring.

5. Where “shipping splits” are required between the control compartments and the starter cubicles, interconnecting jumper wires shall be provided for field re-connection.

6. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring.

7. In general, all conduit entering or leaving a motor control center shall be stubbed up into the bottom horizontal wireway directly below the vertical section in which the conductors are to be terminated, or shall enter the motor control center from the top. Conduits shall not enter the motor control center from the side unless approved in writing by the Owner/Engineer.

8. All field wiring shall be tagged and coded with an identification number as shown on the Drawings. Coding shall be typed on a heat shrinkable tube applied to each end showing origination and destination of each wire. The marking shall be permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal.

E. Surge Protective Devices 1. Furnish where shown on the Drawings, or specified herein, a manufacturer provided and

installed, Low Voltage Surge protective Devices (SPD) (Type 2), as specified in Section 16196 of these Specifications. Connection to the MCC shall be with a surge rated disconnect, mounted integral to the MCC

F. Feeder Protective Devices (Non-Motor Loads) 1. Unless otherwise shown on the Drawings, feeder circuit breakers, 1200 ampere down to

250 amperes, shall be molded case, 3 Pole, 600 Volt, fixed type, manually operated with stored energy closing mechanism. Trip device shall be solid state with adjustable long time pickup, adjustable instantaneous, and overload, short circuit and ground fault indicator lights.

2. Unless otherwise shown on the Drawings, feeder circuit breakers, less than 250 ampere frame, shall be molded case, 3 Pole, 600 Volt, fixed type, manually operated with over-center toggle mechanism.

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3. All circuit breakers above 250 ampere frame and larger, shall have trip units of the modular type for easy changing of trip range.

G. All Main and Feeder circuit breakers shall have provision for padlocking in the OFF position.

H. Control and Instrument Power Transformers. 1. Control power transformers shall be provided where shown on the Drawings.

Transformer shall be sized for the entire load, including space heaters, plus 25% spare capacity.


2.4 MOTOR CONTROLLERS

A. General 1. The Drawings indicate the approximate horsepower and intended control scheme of the

motor driven equipment. Provide the NEMA size starter, circuit breaker trip ratings, control power transformers and thermal overload heater element ratings matched to the motors and control equipment actually supplied, in compliance with the NEC and the manufacturer’s heater selection tables. All variations necessary to accommodate the motors and controls as actually furnished shall be made without extra cost to the Owner.

2. Motor starters shall be as shown on the Drawings. All motor starters shall be combination units, full voltage non-reversing (FVNR), with adjustable instantaneous trip magnetic only circuit breakers, or motor circuit protectors (MCP), unless otherwise specified or shown on the Drawings. NEMA starter sizes and breaker trip ratings shall be as required for the horsepower indicated, but shall be in no case less than NEMA Size 1. If the manufacturer of the equipment utilizing the motor, supplies a motor horsepower larger than that shown on the Drawings, the Contractor shall supply a motor starter sufficient in size to control the motor supplied. International (IEC) starters shall not be acceptable.

3. Each motor starter shall have a 120 volt operating coil unless otherwise noted. 4. NEMA Size 5 and smaller shall be draw out design with stab-on connectors engaging

the vertical buses. Larger units shall be of the fixed (bolt-in) design. 5. Overload relays shall be standard Class 20, ambient compensated, manually reset by

pushbutton located on front of the compartment door. A normally closed contact shall be directly used in the start circuit and a normally open contact shall be wire to a terminal board for overload alarm.

6. Control power transformers shall be 120 volt grounded secondary. Primary shall be fused with slow blow fuses in each phase. One leg of the transformer secondary shall be solidly grounded while the other leg shall be fused. The transformer shall be oversized for auxiliary loads as indicated on drawings, but in no case be smaller than 100 VA.

7. Combination starters shall include a motor circuit protector (MCP) in series with a motor controller and an overload protective device. The MCP shall have an adjustable magnetic trip range in percent of rated continuous current and a trip test feature. MCP's shall be labeled in accordance with UL489.

B. Magnetic Motor Starters 1. Motor starters shall be 2 or 3 pole, single or 3 phase as required, 60 Hertz, 600 volt,

magnetically operated, full voltage non reversing except as shown on the Drawings. NEMA sizes shall be as required for the horsepower shown on the Drawings. IEC rated starters are unacceptable.

2. Each motor starter shall have a 120 volt operating coil, and control power transformer. Starters shall have motor overload protection in each phase. Auxiliary contacts shall be provided as shown on the Drawings. A minimum of one N.O. and one N.C. auxiliary contacts shall be provided in addition to the contacts shown on the Drawings.

3. Overload relays shall be adjustable, ambient compensated and manually reset.

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4. Control power transformers shall be sized for additional load of 100VA or an additional 10% whichever is larger. Transformer primary shall be equipped with slow blow fuses. Control power transformers shall not be located behind other components and shall be accessible for removal or replacement without removing any other component.

5. Built in control stations and indicating lights shall be furnished where shown on the Drawings.

6. All wires shall be terminated on terminal blocks and shall be tagged. 7. The control compartment shall have a pocket on the inside of the door with a copy of the

appropriate schematic and wiring diagram.

C. Combination Magnetic Motor Starters 1. Motor starters shall be a combination motor circuit protector and contactor, 2 or 3 pole,

single or 3 phase as required, 60 Hertz, 600 volts, magnetically operated, full voltage non reversing unless otherwise shown on the Drawings. NEMA starter frame sizes shall be as shown on the Drawings. If the motor supplied by the equipment supplier is larger than that shown on the Drawings, the Contractor shall supply a larger frame size corresponding to the motor supplied. Motor circuit protectors shall be molded case with adjustable magnetic trip only. They shall be specifically designed for use with magnetic motor starters. Motor circuit protectors shall be current limiting type, with additional current limiters if required. IEC rated starters are unacceptable.


3. Overload relays shall be adjustable, ambient compensated and manually reset. 4. Control power transformers shall be sized for additional load of 100VA or an additional

10% whichever is larger. Transformer primary shall be equipped with time delay fuses. 5. Built in control stations and indicating lights shall be furnished where shown on the

Drawings. 6. All wires shall be terminated on terminal blocks and shall be tagged. 7. The control compartment shall have a pocket on the inside of the door with a copy of the

appropriate schematic and wiring diagram.

D. Variable Frequency Drives (VFDs) 1. Fans shall be furnished for soft start starters and Variable Frequency Drives (VFDs), as

required by the manufacturer, to provide air circulation and cooling and shall be as follows: a. The fan shall operate only when the drive is “ON” and for a cool-down period after

the drive has stopped. Otherwise the fan shall not run when the drive is “OFF”. Louvers, if provided, shall have externally removable filters. The filter shall be metallic and washable.

b. Fan motors shall be protected by an input circuit breaker. Metal squirrel cage ball bearing, three phase fan motors with 10-year design life shall be used in the drive design. Plastic muffin fans are not acceptable. Fan power shall be obtained from a tap on the main control power transformer.

c. A “loss of cooling” fault shall be furnished. In the event of clogged filters or fan failure, the drive shall produce an alarm and then, in a predetermined time, shut down safely without electronic component failure.

2. The VFD shall be a sinusoidal Pulse width modulated (PWM) type, with sensor-less Dynamic Torque Vector Control capability, designed for use with standard induction motors, constant or variable torque as required for the load application, with current limiting input fuses, incoming line reactors and/or active filters, circuit breaker disconnect, motor isolation contactor, control transformer overload relays and process signal follower card. Drives shall be UL listed. Variable frequency drives manufactured for HVAC applications are not acceptable.

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3. The Drawings indicate the approximate horsepower and intended control scheme of the motor driven equipment. Provide the VFD, auxiliary components and equipment where shown or specified, and matched to the motors and control equipment actually supplied, in compliance with the NEC. All variations necessary to accommodate the motors and controls as actually furnished shall be made without extra cost to the Owner.

4. The VFD shall be sized for a motor one NEMA size larger than the motor being supplied. 5. The VFD inverter/chopper shall be of the pulse width modulated (PWM), neutral point

clamp (NPC) type, converting the utility input voltage and frequency to a variable voltage and frequency output via a two-step operation. Adjustable Current Source VFDs are not acceptable. The output devices shall be Insulated Gate Bipolar Transistors (IGBTs). Bipolar Junction Transistors, GTOs or SCRs are not acceptable.

6. Drive output voltage shall vary with frequency to maintain a constant volts/hertz ratio up to base speed (60 hertz) output. Constant or linear voltage output shall be supplied at frequencies greater than base speed (60 hertz).

7. The Drive shall be capable of a minimum of 100% rated current in continuous operation. 8. The drive one-minute overload current rating shall be not less than 110% of rated current. 9. Each VFD shall have an HMCP or thermal magnetic circuit breaker to provide a

disconnect means. Operating handle shall protrude through the door. The disconnect shall not be mounted on the door. The handle position shall indicate ON, OFF, and TRIPPED condition. The handle shall have provisions for padlocking in the OFF position with at least three (3) padlocks. Interlocks shall prevent unauthorized opening or closing of the VFD door with the disconnect handle in the ON position. Door handle interlock shall have provision for defeating by qualified maintenance personnel.

10. Where the cables from the VFD to the motor exceed 100 feet in length, a properly sized line reactor shall be installed at the VFD output to reduce dv/dt levels and the resultant peak voltage overshoots at the motor terminals.

11. Make provisions to accept a remote dry contact closure to start and stop the drive(s) with the drive control system in the AUTO mode.

12. Service Conditions a. Input power: MCC voltage plus 10 percent, minus 5 percent, 3 Phase, 60 Hz. b. Input frequency: 57 to 63 Hz. c. Ambient temperature: 0 to 40 degrees C (Enclosed). d. Elevation: Up to 3300 feet above mean sea level. e. Relative humidity: Up to 90 percent non-condensing.

13. Minimum Drive Efficiency: The VFD shall have an efficiency at full load and speed that exceeds 95% for VFDs below 15 HP and 97% for drives 15 HP and above. The efficiency shall exceed 90% at 50% speed and load.

14. Displacement Power Factor: 0.95 or better at any speed, measured at drive input terminals.

15. Drive Output: 100 percent rated current continuous, suitable for operation of the driven equipment over a 30:1 speed range without overloading or low speed cogging. Drives shall be capable of a continuous overload up to 110 percent rated current and a maximum 150 percent overload for 1 minute. Starting torque shall be matched to the load.

16. Voltage Regulation: plus or minus 1 percent of rated value, no load to full load. 17. Output Frequency Drift: No more than plus or minus 0.5 percent from set point. 18. Drives shall withstand five cycle transient voltage dips of up to 15 percent of rated voltage

without an under voltage trip or fault shutdown, while operating a variable torque load. 19. Protection of power semiconductor components shall be accomplished without the use

of fast acting semiconductor output fuses. Subjecting the controller to any of the following conditions shall not result in component failure or the need for fuse replacement. a. Short circuit at controller output b. Ground fault at controller output c. Open circuit at controller output

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d. Input under voltage e. DC bus overvoltage f. Loss of input phase g. AC line switching transients h. Instantaneous overload i. Sustained overload exceeding 115 percent of controller rated current j. Over temperature responsive to a thermal switch in the motor or an overload relay

20. The controller electronics shall contain light emitting diodes (LED's) to monitor and indicate the following conditions. a. Under voltage b. Overvoltage c. Ground Fault d. Instantaneous Overcurrent e. Over temperature f. Power UP Delay/Reset g. Drive Enabled h. Bus Capacitors Charged

21. On each VFD, make provisions to accept a 4 20 mA DC input signal for remote speed control. Input shall be isolated at the drive and active with the drive control system in the AUTO mode.

22. Furnish a 120 VAC control to allow VFD to interface with remote dry contacts. 23. Provide a 4 20 mADC isolated output signal proportional to speed for remote speed

indication. 24. Provide two sets of Form C auxiliary dry contacts for remote indication of VFD running

status. 25. Provide two sets of Form C auxiliary dry contacts for remote indication of VFD fault. 26. The equipment manufacturer shall provide a harmonic analysis showing that the drives

meet IEEE 519 at the Point of common Coupling. The Point of Common coupling shall be defined as the incoming line terminals of the motor control center. Total harmonic distortion shall be calculated under worst-case condition in accordance with the procedure outlined in IEEE Standard 519-1992. Copies of these calculations shall be submitted for approval. The worst case condition of operation is defined as follows: a. All VFDs in the MCC are operating at full speed and all other loads on the MCC

are in the “OFF” condition. 27. The voltage harmonic distortion, at the point of common coupling, shall not exceed 5%

as indicated in Table 10.2 of IEEE 519 28. The current harmonic distortion, at the point of common coupling, shall not exceed the

limits in Table 10.3 of IEEE 519. 29. The harmonic analysis shall include all voltage and current harmonics to the 50th. 30. Each VFD shall, as a minimum, contain a 5% line reactor. The manufacturer shall

additionally use individual matrix filters, or an active harmonic filter on the MCC bus, as shown on the Drawings, for mitigating harmonic distortion. All VFDs of a single drive size shall have the same type and size of mitigating device. Other types of mitigation are not acceptable.

31. In the event that the harmonic distortion does not meet the specified limits in the field tests, the manufacturer shall provide and the Contractor shall provide and install, at no additional expense to the Owner, additional filtering sufficient to meet IEEE 519 as specified. The manufacturer may substitute new VFDs containing matrix filters or an additional section on the MCC containing an active harmonic filter connected to the MCC bus, to meet the specified requirements. All VFDs of a single drive size shall still shall have the same type and size of mitigating device. Any Field modifications to the VFDs, their wiring, their enclosures, or relocation of cells in the MCC requiring motor or control conductor splicing to meet the specified requirements, will not be acceptable.

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32. Compliance shall be verified with onsite field measurements of both the voltage and current harmonic distortion at the point of common coupling with operating conditions as defined above.

E. Harmonic Correction Units 1. Where Harmonic Correction Units are shown on the Drawings as an integral part of the

MCC, the units shall be factory designed as a part of the MCC, for the attenuation of harmonics induced by nonlinear loads such as Variable Frequency Drives.

2. The harmonic correction unit shall be in a totally enclosed dead-front, free-standing MCC assembly. Structures shall be 90 inches high and 21 inches deep for front-mounted units. Structures shall contain a horizontal wireway at the top, isolated from the horizontal bus by metal barriers and shall be readily accessible through a hinged cover. Adequate space for conduit and wiring to enter the top or bottom shall be provided without structural interference.

3. An operating mechanism shall be mounted on the primary of each harmonic correction unit. It shall be mechanically interlocked with the door to prevent access unless the disconnect is in the “OFF” position. A defeater shall be provided to bypass this interlock. With the door open, an interlock shall be provided to prevent inadvertent closing of the disconnect. Padlocking facilities shall be provided to positively lock the disconnect in the “OFF” position with from one (1) to three (3) padlocks with the door open or closed.

4. Harmonic Correction Units shall be disconnected from the power source by a molded case switch. All units shall include 200,000 AIC rated fuses with Class T actuation. All units shall be provided with a grounding lug. Grounding by the Contractor shall be performed according to local and national standards.

5. The harmonic correction units shall be sized to meet 5% total harmonic current distortion {THD (I)}, and <5% total harmonic voltage distortion {THD (V)} levels as defined by IEEE 519-1992 at the incoming line terminals of the VFD.

6. The harmonic correction unit shall be designed in accordance with the applicable sections of the following standards. Where a conflict arises between these standards and this specification, this specification shall govern. a. ANSI IEEE standard C62.41-1991 Surge Withstand Capacity b. CSA 22.2, No. 14 & 66 CSA requirements for power electronics c. FCC Part 15, Sub Part J, Class A RFI/EMI emission standards d. ANSI IEEE standard 519-1992 Harmonic limits e. UL 508C UL requirements for power conversion equipment f. ICBO Building Code, Section 16, Seismic Zone 4 Vibration Standard

7. The motor control center manufacturer shall install the harmonic correction unit in the motor control center. The harmonic correction unit shall be approved by UL or CSA for installation in the motor control center.

8. Modes of Operation a. The harmonic correction unit shall be designed to electronically inject harmonic

current to cancel load produced harmonic current such that the upstream power harmonic current and voltage are reduced to below 5% TDD and 5% THD (V) as defined by ANSI IEEE standard 519-1992 for load demand and voltage distortion limits. TDD as used herein refers to the total load demand of the applied circuit. The applied circuit may be a single nonlinear load, an entire distribution bus load, or the facility load at the Point-of-Common Coupling (PCC)

b. Reactive current compensation (displacement power factor correction) shall be activated via a digital keypad/display mounted on the door of the enclosure. When reactive current compensation is activated, the harmonic correction unit shall first perform harmonic current correction and then use the remaining capacity to inject reactive current compensation to the specified level herein defined

9. Design a. Each unit of the harmonic correction units shall meet FCC Part 15, Sub Part J

Class A requirements for both radiated and conducted EMI.

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b. All harmonic correction units shall be defined as a power electronic device consisting of power semiconductors that switch into the AC lines to modulate its output to cancel detrimental harmonic and/or reactive currents. A DC bus shall store power for power semiconductor switching. A microprocessor shall control the operation of the power converter.

c. Each unit shall be designed with a current limiting function to protect the semiconductors. When this level is attained, a message shall be displayed indicating the output capacity is at-maximum capacity and actuate the at-maximum capacity relay. Operation shall continue indefinitely at this level without trip off or destruction of the power correction unit.

d. Two distinct levels of faults shall be employed. Non-critical level faults shall provide automatic restart and a return to normal operation upon automatic fault clearance. Critical level faults stop the function of the unit and await operator action 1) Faults such as ac line over-voltage, AC line under-voltage, AC line power

loss, and AC line phase imbalance shall be automatically restarted. Upon removal of these fault conditions, the power correction system shall restart without Operator action. Automatic restart shall not occur if 5 faults have occurred in less than 5 minutes. During the fault condition, except line loss, the display shall state the type of fault and indicate that automatic restart will occur. The run relay and run LED shall be disabled. The fault relay shall not be enabled unless time out occurs. Upon AC line loss, the power-on relay shall be disabled and no display shall be provided.

2) All other types of faults shall be considered critical and stop the power correction system. The display shall indicate the fault condition and “STOP.” The run LED and relay shall be disabled and the fault relay enabled. The Operator shall be required to initiate a power reset (turn power OFF and ON) to restart the power correction system.

e. The logic of the harmonic correction unit shall monitor the load current by utilizing two (2) current transformers (CTs) mounted on phases A and B to direct the function of the power electronic converter. A third current transformer is required if single-phase or three-phase line-to-neutral connected loads are present downstream from the location of the CTs. The ratio of the CTs shall be entered into the logic via the digital keypad/display to calibrate the operation of the power correction system. The output of the current transformers shall be 5 amperes

f. Up to three (3) harmonic correction units may be installed in parallel to inject current according to the information received from one set of CTs. The units will function independently. If one unit is stopped or faulted, the remaining units will adjust accordingly to maintain optimum harmonic cancellation levels up to the capacity of the remaining units

10. Performance Requirements a. Input Power:

1) Voltage: Same as MCC service. 2) Voltage Tolerance: +/- 10% of nominal 3) Frequency: 60 Hz, +/- 5% 4) Current Limit: 100% of rating 5) Surge Withstand Capability: ANSI/IEEE std. C62.41-1991 without damage

11. Output Performance a. Performance of the harmonic correction unit shall be independent of the

impedance of the power source. All performance levels shall be attained whether on the ac lines or backup generator or output of the uninterruptible power supply (UPS)

b. Harmonic Correction: 1) Limit 2nd through 50th order harmonic current to <5% TDD as defined in

ANSI/IEEE STD 519-1992 at each installed location. Harmonic levels for

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individual harmonic orders shall comply with respective levels established in ANSI/IEEE STD 519-1992.

2) Limit the THD (V) added to the electrical system immediately upstream of the power correction system location(s) to less than or equal to 5% as defined in ANSI/IEEE STD 519-1992. The power correction system shall not correct for utility supplied voltage distortion levels.

c. Reactive Current Compensation: to .95 lagging displacement power factor. Leading power factor is not permitted

12. Environmental Conditions a. The harmonic correction unit shall be able to withstand the following environmental

conditions without damage or degradation of operating characteristics or life 1) Operating Ambient Temperature: 0 degrees C (32 degrees F) to 40 degrees

C (104 degrees F). 2) Storage Temperature: -40 degrees C (-40 degrees F) to 65 degrees C (149

degrees F). 3) Relative Humidity: 0 to 95%, non-condensing. 4) Altitude: Operating to 2000 meters (6500 ft). Derated for higher elevations. 5) Audible Noise: Generated by power correction system not to exceed 65 dbA

measured 1 meter from surface of unit. 6) Vibration: Seismic Zone 4.

13. Current Transformers a. Split core type current transformers shall be installed as defined herein and shown

in the electrical drawings. Current transformers shall be rated for the total rated RMS current of the total load at each installed location.

b. Two current transformers per power correction system location shall be provided and shall be mounted on phases A and B. A third current transformer shall be provided if single or three-phase line-to-neutral connected loads are present downstream from the location of the CTs.

c. Each current transformer shall have a current output of 5 amperes. Current capacity of each current transformer shall be 5000, 3000, 1000 or 500, as required for the electrical system where installed. No other ratings are acceptable.

d. Each current transformer shall be rated for 400 Hz. 14. Operator Controls and Interface

a. All units shall include a digital interface model (DIM) that includes an alphanumeric display to clearly display information. All information shall be in English. Operators include run, stop, setup, enter, and up/down scroll.

b. The display shall provide operating data while functioning. Standard operating parameters available for display are ac line voltage, total RMS load current, harmonic current of load, reactive current of load, output harmonic and reactive current of power correction system.

c. When the output of the power correction unit is at full rated capacity, the display shall indicate at-maximum capacity and actuate an at-maximum capacity relay.

d. All fault conditions shall be displayed as they occur. Diagnostic information shall be provided in English and clearly indicate the nature of the fault.

e. The run pushbutton shall include a red LED. LED shall be lighted when unit is running.

f. Contacts shall be provided for operator information for power-on, run, fault and at-maximum capacity. Each contact shall be rated for 1 ampere at 120/240 volts. One Form C contact shall be provided for each relay.

15. An RS-485 serial communication port shall be provided for remote control and diagnostic information.

F. Control Relays 1. Control relays shall be 300 volt, industrial rated, plug-in socket type, housed in a

transparent polycarbonate dust cover, designed in accordance with UL Standard 508 for motor controller duty. Continuous contact rating shall be 10 amperes resistive, ¼ HP at

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120 VAC, operating temperature minus 10 to plus 55 degrees C. Provide spare N.O. & N.C. contacts. Relays shall be Potter & Brumfield KRP Series or equal with neon coil indicator light. Timing relays shall be 300 Volt, solid state type, with rotary switch to select the timing range.

2.5 ACCESSORIES

A. Provide the following accessories. 1. Furnish and install a non-conducting switchboard floor mat, minimum 3/8-inch-thick by 3

feet wide, meeting ANSI/ASTM D-178-01 Type 2 Class 3, Wearwell 702 or equal, and extending the full length of the equipment lineup.

2.6 SPARE PARTS

A. Provide the following spare parts: 1. 3 – Control fuses of type used. 2. One dozen each of cover bolts, spring nuts and door fasteners. 3. One quart of touch-up paint.


2.7 FIELD TESTING

A. The Motor Control Center shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer’s routine shop tests and any other additional operational test to insure the workability and reliable operation of the equipment.

B. Prior to factory testing, the manufacturer shall check to see that all selections and settings required by the Power System Study Engineer have been performed.

C. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards.

D. The operational test shall include the proper connection of supply and control voltage and, as far as practical, a mockup of simulated control signals and control devices shall be fed into the boards to check for proper operation.

E. The manufacturer shall provide three (3) certified copies of factory test reports as specified in Paragraph 1.03D.

PART 3 - EXECUTION


A. Provide the services of a qualified factory-trained manufacturer's field engineer to assist the Contractor in installation and start-up of the equipment specified under this Section for a period of not less than 2 working days, with not less than one working day per motor control center. The manufacturer's field engineer 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.

B. The Contractor shall provide three (3) copies of the manufacturer's field testing report.

3.2 VARIABLE FREQUENCY DRIVES INSTALLATION

A. The Contractor shall provide the services of a manufacturer’s field engineer to assist the Contractor in installation, adjusting, programming, startup, testing and training on the VFDs furnished and installed as a part of the MCCs.

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A. Installer shall be specialized in installing low voltage motor control centers with minimum 5 years documented experience. Experience documentation shall be submitted for approval prior to beginning work on this project.

3.4 EXAMINATION


B. Housekeeping pads shall be included for the motor control centers as detailed on the Drawings with the exception of motor control centers which are to be installed adjacent to an existing unit. Housekeeping pads for these (if used) should match the existing installation.




3.5 INSTALLATION






3.7 FIELD ADJUSTING


B. The Power Monitoring and Protective Relays shall be set in the field by a qualified representative of the manufacturer, retained by the Contractor, in accordance with settings designated in a coordinated study of the system as required in Section 16105 Power System Study. All such settings, including the application of arc flash labels, shall have been made and Approved by the Owner/Engineer, prior to energizing of the equipment.

3.8 FIELD TESTING

A. The manufacturer’s field engineer shall make all electrical field tests recommended by the manufacturer. Disconnect all connections to solid-state equipment prior to testing.

B. Megger and record phase to phase and phase to ground insulation resistance of each bus section. Megger, for 1 minute, at minimum voltage of 1000 VDC. Measured Insulation resistance shall be at least 100 megohms. In no case shall the manufacturer’s maximum test voltages be exceeded.

C. Complete the following test forms: 1. Motor Control Center Test Report: Before energizing the motor control center, the

Contractor shall perform megohm meter tests. The measurements shall be made on all phase busing and the data checked for conformance with typical manufacturer’s data. The tests shall adhere to manufacturer’s testing recommendations for the proper testing methods and test voltage levels for each piece of equipment. Readings that fall below manufacturer’s recommended values will not be acceptable and the Contractor shall be

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required to perform any necessary remedial action before the busing is energized. A data sheet shall be submitted to the Owner/Engineer for the MCC. The test report shall include the following equipment information: a. MCC 7, 8 and 9 b. MCC 7 and 8 MANUFACTURER: General Electric Corp. c. MCC 9 MANUFACTURER: Square D Company d. MCC 7, 8 and 9 NAMEPLATE DATA:

VOLTS: HORIZONTAL BUS AMPS: MAIN BREAKER AMPS:

e. INSULATION TEST (MEASURED): PHASE A-B: PHASE B-C: PHASE C-A: PHASE A-G: PHASE B-G: PHASE C-G:

f. EQUIPMENT DISCONNECTED DURING TEST: g. DATE OF TEST: h. TESTED BY:

D. Where test reports show unsatisfactory results, the Owner/Engineer may require the removal of all defective or suspected materials, equipment and/or apparatus, and their replacement with new items, all at no cost to the Owner. The Contractor shall bear all cost for any retesting.

E. The manufacturer’s field engineer shall perform field measurements, of both the voltage and current harmonic distortion at the point of common coupling with operating conditions to determine compliance with the Specifications.

3.9 CLEANING





A. A qualified factory-trained manufacturer's representative shall personally inspect the equipment at the jobsite and shall certify in writing that the equipment has been installed, adjusted, and tested, in accordance with the manufacturer’s recommendations, including all settings designated in the Power System Study.

B. The Contractor shall provide three (3) copies of the manufacturer's representative's certification.

3.12 TRAINING

A. Provide manufacturer's services for training of plant personnel in operation and maintenance of the equipment furnished under this Section.

B. The training shall be for a period of not less than one (1) eight-hour day.

C. The cost of training program to be conducted with Owner's personnel shall be included in the Contract Price. The training and instruction, insofar as practicable, shall be directly related to the system being supplied.

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D. Provide detailed O&M manuals to supplement the training course. The manuals shall include specific details of equipment supplied and operations specific to the project.

E. The training session shall be conducted by a manufacturer's qualified representative. Training program shall include instructions on the assembly, motor starters, protective devices, metering, and other major components.

F. The Owner reserves the right to videotape the training sessions for the Owner’s use.

END OF SECTION

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LOW VOLTAGE MOTOR CONTROLLERS AND CONTACTORS Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16481 LOW VOLTAGE MOTOR CONTROLLERS AND CONTACTORS.DOCX

SECTION 16481 LOW VOLTAGE MOTOR CONTROLLERS AND CONTACTORS

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The Contractor shall furnish and install low voltage motor controllers, together with appurtenances, complete and operable, as specified herein and as shown on the Contract Drawings.

1.2 RELATED WORK




D. Section 16120 Wires and Cables (600 Volt Maximum

E. Section 16196 Low Voltage AC Surge Protective Devices (SPDs)

F. Section 16033 Cast-In-Place Concrete for Electrical Applications

G. Process Equipment Division 11 Specifications

H. Instrumentation Equipment Division 17 Specifications

I. Mechanical Equipment Division 15 Specifications

J. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

K. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS


B. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will also be returned unreviewed.

C. The original equipment manufacturer shall create all equipment shop drawings, including all wiring diagrams, in the manufacturer’s Engineering department. All equipment shop drawings shall bear the original equipment manufacturers logo, drawing file numbers, and shall be maintained on file in the original equipment manufacturer’s archive file system. Photocopies of the Engineer’s ladder schematics are unacceptable as shop drawings.

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D. Submit to the Owner/Engineer, shop drawings and product data, for the following: 1. Product data sheets and catalog numbers for overcurrent protective devices, motor

starters, control relays, control stations, meters, pilot lights, etc. The manufacturer’s name shall be clearly visible on the each cut sheet submitted. List all options, trip adjustments and accessories furnished specifically for this project. Clearly mark each sheet to indicate which items apply and/or those items that do not apply.

2. Provide control systems engineering to produce custom unit elementary drawings showing interwiring and interlocking between components and to remotely mounted devices. Include and identify all connecting equipment and remote devices on the schematics. The notation “Remote Device” will not be acceptable. Show wire and terminal numbers. Indicate special identifications for electrical devices per the Drawings.

3. Provide plan and elevation drawings of each controller or enclosure, with dimensions and exterior controls.

4. Schematic diagram, including manufacturer’s selections of component ratings, and CT and PT ratios.

5. Nameplate schedule 6. UL Listing of the completed assembly. 7. Component list with detailed component information, including original manufacturer’s






E. Factory Tests. Submittals shall be made for factory tests specified herein.

F. Field Test Reports. Submittals shall be made for field tests specified herein.

G. Operation and Maintenance Manuals. 1. Operation and maintenance manuals shall include the following information:


above.

H. The manufacturer shall submit for approval, a training agenda for all training specified herein. Training agenda shall not be submitted until final approval of the Operation and Maintenance Manual.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA Standard ICS 2 – 2000 Industrial Control and Systems 2. NFPA 70 – National Electrical Code (NEC) 3. NFPA 70E – Standard For Electrical Safety in the Workplace

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B. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly. All assemblies shall be of the same manufacturer. Equipment that is manufactured by a third party and “brand labeled” will not be acceptable.


D. Equipment submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.


F. Equipment submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.



B. Equipment shall be handled and stored in accordance with manufacturer's instructions.



1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 2 years from date of final acceptance of the equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Manufacturer, at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Eaton Cutler Hammer 2. General Electric Co. 3. Square D 4. Allen Bradley


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2.2 RATINGS

A. The service voltage, shall be as shown on the Drawings. The overall short circuit withstand and interrupting rating of the equipment and devices shall be equal to or greater than the overall short circuit withstand and interrupting rating of the feeder device immediately upstream of the motor controller. Systems of motor controllers employing series connected ratings for main and feeder devices shall not be used. Motor starter units shall be tested and UL labeled for the specified short circuit duty in combination with the motor branch circuit protective device.

B. Motor controllers, including associated devices, shall be designed for continuous operation at rated current in a 40 degree C ambient temperature.

C. For additional ratings and construction notes, refer to the Drawings.

2.3 CONSTRUCTION


ratings of devices, bus bars, components; protective relays, voltage ratings of devices, components and assemblies; and other required details.

2. Control units shall be arranged as shown on the Drawings. 3. Where the equipment contains a programmable logic controller (PLC) or a uninterruptible

power supply (UPS), the equipment manufacturer shall furnish factory installed, a dedicated Point of Utilization Device (SPD), as specified in Section 16196, Individual Control Panel and Related Equipment Protection (Type 3).


1) Nameplates shall be engraved, laminated impact acrylic, matte finish, not less than 1/16-in thick by 3/4-in by 2-1/2-in, Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures except for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”, or equal. Prior to installing the nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residue has been removed. Epoxy adhesive or foam tape is not acceptable.

b. Internal 1) Control components mounted within the assembly, such as fuse blocks,






b. Indicator lamps shall be LED type. For all control applications, indicator lamps shall incorporate a push-to-test feature. Lens colors shall be as follows: 1) Red for ON, Valve OPEN, and Breaker CLOSED. 2) Green for OFF, Valve CLOSED and Breaker OPEN. 3) Amber for FAIL.

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4) Blue for READY 5) White for POWER ON.







a. Each enclosure shall incorporate a removable back panel, and side panels, on which control components shall be mounted. Back panel shall be secured to the enclosure with collar studs for wall mounted enclosures, and 316 SS hardware for free standing enclosures.


c. The enclosure door shall be interlocked with the main circuit breaker by a panel mounted cable driven operating mechanism.

d. Back panel shall be tapped to accept all mounting screws. Self-tapping screws shall not be used to mount any components.

e. All enclosure doors shall have bonding studs. The enclosure interior shall have a bonding stud.

f. Each enclosure shall be provided with a documentation pocket on the inner door. g. Enclosures shall not have holes or knockouts. h. Provide manufacturer’s window kits where shown on the Drawings. i. All panels installed outdoors shall have a factory applied, suitable primer and final

coat of weatherproof white paint. j. All enclosures shall be padlockable.



b. Manufacturers 1) Cooper Crouse Hinds Type EJB, Style C 2) Appleton Electric Type AJBEW 3) Approved Equal



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b. Manufacturers 1) Hoffman Polypro 2) Hubbell-Wiegmann Non-Metallic 3) Approved Equal


1) Type 5052 aluminum, body and door 2) Stainless steel continuous hinge 3) Foam in-place gasket 4) Single point quarter turn latches (20”x24” and below). All others 3-point latch

b. Manufacturers 1) Hoffman Comline 2) EMF Company 3) NEMA Enclosures Company 4) Hammond Company 5) Approved Equal

5. NEMA 12 a. NEMA 12 Aluminum



6. Not Defined a. Where an enclosure is not otherwise defined or shown on the Drawing

1) NEMA 4X 316 Stainless Steel 2) Type 316 stainless steel, body and door 3) Stainless steel continuous hinge 4) Foam in-place gasket 5) Single point quarter turn latches (20”x24” and below). All others 3-point latch

b. Manufacturers 1) Hoffman Concept Series 2) EMF Company 3) NEMA Enclosures Company 4) Hammond Company 5) Approved Equal

7. NEMA 1 or NEMA 1A boxes shall not be used. 8. Malleable iron boxes shall not be used.

C. Internal Wiring 1. Wiring: Stranded copper, minimum size No. 14 AWG, with 600 Volt, 90-degree C, flame

retardant, Type MTW thermoplastic insulation, NEMA Class II, Type B wiring. Line side power wiring shall be sized for the full rating or frame size of the connected device.

2. All wiring shall be tagged and coded with an identification number as shown on the Drawings. Coding shall be typed on a heat shrinkable tube applied to each end showing origination and destination of each wire. The marking shall be permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal.


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D. Field Installed Internal Wiring 1. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie

wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundled separately from the rest of the control wiring.

2. All field wiring shall be tagged and coded with an identification number. Coding shall be typed on a heat shrinkable tube applied to each end of the wire. The marking shall be a permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal

3. In general, all conduit entering or leaving equipment shall be stubbed up into the bottom of the enclosure directly below the area in which the conductors are to be terminated, or from the top if shown on the Drawings. Conduits shall not enter the side unless approved in writing by the Owner/Engineer.

4. Where elapsed time meters are specified or shown on the Drawings, a six digit, non-resettable elapsed time meter shall be installed on the face of each motor starter. Meter shall be as specified in Section 16195.

E. Control and Instrument Power Transformers 1. Control power transformers shall be provided where shown on the Drawings.

Transformer shall be sized for the entire load, including space heaters, plus 25% spare capacity, and not less than 100VA.



A. General 1. The Drawings indicate the approximate horsepower and intended control scheme of the

motor driven equipment. Provide the NEMA size starter, circuit breaker trip ratings, control power transformers and thermal overload heater element ratings matched to the motors and control equipment actually supplied, in compliance with the NEC and the manufacturer’s heater selection tables. All variations necessary to accommodate the motors and controls as actually furnished shall be made without extra cost to the Owner.

2. Furnish lugs for incoming wiring, sizes as shown on the Drawings. Allow adequate clearance for bending and terminating of cable size and type specified.

3. Motor starters shall be as shown on the Drawings. All motor starters shall be combination units, full voltage non-reversing (FVNR), with adjustable instantaneous trip magnetic only circuit breakers, or motor circuit protectors (MCP), unless otherwise specified or shown on the Drawings. NEMA starter sizes and breaker trip ratings shall be as required for the horsepower indicated, but shall be in no case less than NEMA Size 1. If the manufacturer of the equipment utilizing the motor, supplies a motor horsepower larger than that shown on the Drawings, the Contractor shall supply a motor starter sufficient in size to control the motor supplied. International (IEC) starters shall not be acceptable.

4. Each motor starter shall have a 120 volt operating coil unless otherwise noted. 5. Overload relays shall be standard Class 20, ambient compensated, manually reset by

pushbutton located on front of the starter door. A normally closed contact shall be directly used in the start circuit and a normally open contact shall be wire to a terminal board for overload alarm.

6. Combination starters shall include a motor circuit protector (MCP) in series with a motor controller and an overload protective device. The MCP shall have an adjustable magnetic trip range up to 1000 percent minimum of rated continuous current and a trip test feature. MCP's shall be labeled in accordance with UL489.


magnetically operated, full voltage non reversing except as shown on the Drawings.

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NEMA sizes shall be as required for the horsepower shown on the Drawings. IEC rated starters are unacceptable.


3. Overload relays shall be adjustable, ambient compensated and manually reset. 4. Built in control stations and indicating lights shall be furnished where shown on the

Drawings. 5. All wires shall be terminated on terminal blocks and shall be tagged. 6. Provide an as-built wiring diagram and schematic, and post it in a protective cover inside

the cell.

C. Combination Magnetic Motor Starters 1. Motor starters shall be a combination motor circuit protector and contactor, 2 or 3 pole,

single or 3 phase as required, 60 Hertz, 600 volt, magnetically operated, full voltage non reversing unless otherwise shown on the Drawings. NEMA sizes shall be as required for the horsepower shown on the Drawings. Motor circuit protectors shall be molded case with adjustable magnetic trip only. They shall be specifically designed for use with magnetic motor starters. Motor circuit protectors shall be current limiting type, with additional current limiters if required. IEC rated starters are unacceptable.



Drawings. 5. All wires shall be terminated on terminal blocks and shall be tagged. 6. Provide as built wiring diagram and schematic, and post it inside the enclosure.

D. Control Relays 1. Control relays shall be 300 volt, industrial rated, plug-in socket type, housed in a

transparent polycarbonate dust cover, designed in accordance with UL Standard 508 for motor controller duty. Continuous contact rating shall be 10 amperes resistive, ¼ HP at 120 VAC, operating temperature minus 10 to plus 55 degrees C. Provide spare N.O. & N.C. contacts. Relays shall be Potter & Brumfield KRP Series or equal, or solid state, with neon coil indicator light. Timing relays shall be 300 Volt, solid state type, with rotary switch to select the timing range.

2.5 REMOTE MONITORING AND CONTROL INTERFACE

A. General: All control and interconnection points from the equipment to the plant control and monitoring system shall be brought to a separate connection box. No field connections shall be made directly to the equipment control devices. Functions to be brought out shall be as described in the Control Strategies in Section 13400.

B. Discrete control or status functions shall be form C relays with contacts rated at 120 volts AC. Analog signals shall be isolated from each other.

C. Equipment functions to be directly interfaced to the Plant Control and Monitoring System, shall be designed for operation with an Ethernet Connection.

D. The equipment manufacturer shall factory enter the proper IP Address for such connection. Upon request by the Contractor, the Owner/Engineer will provide the proper Internet Protocol Address (IP Address), to be configured by the equipment manufacturer.

E. Refer to Instrumentation Input Output List for monitored parameters.

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F. Communication 1. For remote monitoring, one of the following communication capabilities shall be provided:

a. One (1) integral 10/100BaseT Ethernet port supporting Modbus TCP, Ethernet IP and SNMP protocols.

b. One (1) media protocol converter, interfacing the provided equipment to a 10/100BaseT Ethernet port supporting Modbus TCP, Ethernet IP and SNMP.

2. The protocol interface shall implement the following: a. All data shall be available and/or mirrored within the Modbus 4x or "Holding

Register" memory area. b. Register 4x00001 shall exist and be readable to allow simple, predictable "comm

tests". 3. The media protocol converter shall meet the following criteria:

a. The converter shall support 10/100Base-T Ethernet. The serial port speed (baud rate) shall support 230kbps. The protocol shall support Modbus TCP, Ethernet IP, DF1, and Modbus RTU/ASCII. Protocol shall be Web Browser configurable.

b. Operating limits shall be 0-60 degrees C, with humidity range minimum of 5-90 percent. Shock capability on the serial port shall be ESD +15 kV air GAP meeting IEC 1000-4-2. Power requirements shall be 9-30VDC at 0.5A minimum.

c. The converter shall have LED status for serial, signals, power, and Ethernet. d. The converter housing shall be UL 1604, Class 1 Div 2, DIN Rail mountable. The

converter shall have DB-9M port connection, with screw terminals, to the input. e. Converter shall be Digi One IAP, or approved equal.

2.6 SPARE PARTS

A. Provide the following spare parts: 1. 3 – Control fuses of type used. 2. One dozen each of cover bolts, spring nuts and door fasteners. 3. One quart of touch-up paint.


2.7 FACTORY TESTING

A. The motor controllers shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer’s routine shop tests and any other additional operational test to insure the workability and reliable operation of the equipment.

B. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards.

C. The operational test shall include the proper connection of supply and control voltage and, as far as practical, a mockup of simulated control signals and control devices shall be fed into the boards to check for proper operation.

D. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards, and shall be subject to the Owner/Engineer’s approval.

PART 3 - EXECUTION


A. Installer shall be specialized in installing low voltage motor controllers with minimum 5 years documented experience. Experience documentation shall be submitted for approval prior to beginning work on this project.

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3.2 EXAMINATION


B. Housekeeping pads shall be included for the floor mounted motor controllers as detailed on the Drawings with the exception of motor controllers which are to be installed adjacent to an existing unit. Housekeeping pads for these (if used) should match the existing installation.




3.3 INSTALLATION






3.5 FIELD ADJUSTING



3.6 FIELD TESTING


B. Megger and record phase to phase and phase to ground insulation resistance. Megger, for 1 minute, at minimum voltage of 1000 VDC. Measured Insulation resistance shall be at least 100 megohm. In no case shall the manufacturer’s maximum test voltages be exceeded.

C. Test each key interlock system for proper functioning.

D. Test all control logic before energizing the motor or equipment.

3.7 CLEANING

A. Remove all rubbish and debris from inside and around the motor controllers. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.



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A. A qualified factory-trained manufacturer's representative shall certify in writing that the equipment has been installed, adjusted, including all settings designated in the Power System Study, and tested in accordance with the manufacturer's recommendations.


END OF SECTION

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LOW VOLTAGE VARIABLE FREQUENCY DRIVES (VFDS) Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16485 LOW VOLTAGE VARIABLE FREQUENCY DRIVES (VFDS).DOCX

SECTION 16485 LOW VOLTAGE VARIABLE FREQUENCY DRIVES (VFDs)

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The Contractor shall furnish and install separately enclosed low voltage adjustable frequency drives, together with appurtenances, complete and operable, as specified herein and as shown on the Contract Drawings. For the purpose of this Specification, the terms, VFD, ASD. AFD and Inverter are synonymous.

B. All equipment supplied under this Section of the Specifications shall be products of the same Manufacturer, and shall be contained in one single submittal. Partial submittals will be returned without review. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph herein. Incomplete submittals not containing the required information on the related equipment will also be returned without review.

C. Equipment specified in the Process Equipment Division and supplied as an integral part of a process equipment manufacturer’s package, but referred to this Section for component details, shall be submitted with the manufacturer’s package submittal under the Process Equipment Sections.

D. The minimum requirements for functionality, and control and alarm inputs and outputs, are specified herein. Additional requirements shall be as specified in the Process Equipment Division, Instrumentation Division Equipment, Mechanical Division Equipment and the Contract Drawings.

E. The VFD manufacturer shall coordinate with the motor manufacturer for the motor being furnished, and shall provide a certification that the VFD is suitable for the application.

1.2 RELATED WORK




D. Section 16475 Low Voltage Enclosed Circuit Breakers and Disconnect Switches

E. Section 16105 Power System Study

F. Concrete and Structural Divisions – Concrete Pads

G. Process Equipment Division 11 Specifications

H. Instrumentation Equipment Division 17 Specifications

I. Mechanical Equipment Division 15 Specifications

J. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

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K. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS


B. Submittals for equipment and materials, furnished under this Section of the Specifications, will not be accepted prior to approval of the Power System Study specified under Section 16105. Submittals made prior to such approval will be returned without review.

C. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will also be returned without review.

D. The original equipment manufacturer shall create all equipment shop drawings, including all wiring diagrams, in the manufacturer’s Engineering department. All equipment shop drawings shall bear the original equipment manufacturer’s logo, drawing file numbers, and shall be maintained on file in the original equipment manufacturer’s archive file system. Photocopies of the Engineer’s ladder schematics are unacceptable as shop drawings.

E. Submit to the Owner/Engineer, shop drawings and product data, for the following: 1. Product data sheets and catalog numbers for all components of the drives, including

motor contactors, drive components, control relays, control stations, meters, pilot lights, etc. The manufacturer’s name shall be clearly visible on the each cut sheet submitted. List all options, trip adjustments and accessories furnished specifically for this project. Clearly mark each sheet to indicate which items apply and/or those items that do not apply.

2. Provide drive performance specifications. 3. Provide control systems engineering to produce custom unit elementary drawings

showing internal and external wiring and interlocking between components and to remotely mounted devices. Include and identify all connecting equipment and remote devices on the schematics. The notation “Remote Device” shall not be acceptable. Show wire and terminal numbers. Indicate special identifications for electrical devices per the Drawings.

4. Provide plan and elevation drawings of each controller or enclosure, with dimensions, exterior and interior views, showing component layouts, controls, terminal blocks, etc.

5. Schematic diagram, including manufacturer’s selections of component ratings, and CT and PT ratios.

6. Nameplate schedule 7. UL Listing of the completed assembly 8. Component list with detailed component information, including original manufacturer’s




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F. Certification that the VFD being supplied is suitable for the application.

G. Factory Tests. Submittals shall be made for factory tests specified herein.

H. Field Test Reports. Submittals shall be made for field tests specified herein.

I. Operation and Maintenance Manuals. 1. Operation and maintenance manuals shall include the following information:


above.

J. The manufacturer shall submit for approval, a training agenda for all training specified herein. Training agenda shall not be submitted until final approval of the Operation and Maintenance Manual.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA Standard ICS 2 – 2000 Industrial Control and Systems 2. NFPA 70 – National Electrical Code (NEC) 3. NFPA 70E – Standard For Electrical Safety in the Workplace 4. IEEE 519 (latest revision) - Guide for Harmonic Control and Reactive Compensation of

static Power Converters 5. UL 489 – Standard for Safety for Molded-Case Circuit Breakers 6. UL 508C – Power Conversion Equipment 7. NEMA ICS 2 – Starters, Contactors, Overload Relays, Rated Not More Than 200 Volts

AC or 750 Volts DC. 8. NEMA ICS 6 – Industrial Control and Systems Enclosures 9. NEMA ICS 7.0 – Industrial Controls & Systems for VFD 10. IEC 61200-2 – Vibration Levels 11. IEC 61800-02 and -3 – Adjustable Speed Electrical Power Drive Systems

a. Fulfill all EMC immunity requirements 12. EN 50082-1 and -2 – Test Standards

B. In the case of conflict between the requirements of this Section and those of the listed documents, the requirements of this Section shall prevail.

C. All equipment components and completed assemblies specified in this Section of the Specifications shall bear the appropriate label of Underwriters Laboratories.





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D. For the equipment specified herein, the manufacturer shall be ISO 9001 2000 certified.

E. Equipment submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.





D. Equipment shall be installed in its permanent finished location shown on the Drawings within seven (7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7) calendar days, the equipment shall not be delivered to the site, but stored offsite, at the Contractor’s expense, until such time that the site is ready for permanent installation of the equipment.

E. Where space heaters are provided in equipment, provide temporary electrical power and operate space heaters during storage, and after equipment is installed in permanent location, until equipment is placed in service.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 3 years for 75 HP VFDs, and 5 years for larger than 75 HP, to commence on the date of final acceptance of the equipment. Within such period of warranty, the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment or components shall be performed by the Manufacturer, at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Cutler Hammer 2. General Electric Co. 3. Square D 4. Allen Bradley 5. WEG

B. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specified ratings, features, and functions.

C. All equipment furnished under this Section shall be of the same manufacturer.

2.2 RATINGS

A. Service Conditions

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1. The Drawings indicate the approximate horsepower and intended control scheme of the motor driven equipment. Provide the VFD, auxiliary components and equipment where shown or specified, and matched to the motors and control equipment actually supplied, in compliance with the NEC. All variations necessary to accommodate the motors and controls as actually furnished shall be made without extra cost to the Owner.

2. The service voltage, shall be as shown on the Drawings. The overall short circuit withstand and interrupting rating of the VFD and devices shall be equal to or greater than the overall short circuit withstand and interrupting rating of the feeder device immediately upstream of the adjustable frequency drives. Adjustable frequency drives shall be tested and UL labeled for the specified short circuit duty in combination with the motor branch circuit protective device.

3. The drive shall be UL and cUL listed and not require external fuses. The drive shall also be CE labeled and comply with standards EN 61800-3 for EMC compliance and EN 61800-2 for low voltage compliance.

4. The drive shall be capable of operating in compliance with IEEE 519-1992. 5. Input power: Selectable for 200-240 or 380-480 VAC, 3-phase power input. 6. Input frequency: 57 to 63 Hz. 7. Ambient temperature: Operate at full rated load in an environment with the temperature

between -10 degrees C and 50 degrees C (Enclosed). 8. Elevation: Up to 3300 feet above mean sea level. 9. Relative humidity: Up to 90 percent non-condensing.

B. The VFD, for both constant and variable torque applications, shall be sized for a motor one NEMA size larger than the motor being supplied.

C. The VFD output shall be 100 percent rated current continuous, suitable for operation of the driven equipment over a 30:1 speed range without overloading or low speed cogging. Drives shall be capable of a continuous overload up to 110 percent rated current and a maximum 150 percent overload for 1 minute. Starting torque shall be matched to the load.

D. Rated output voltage shall be programmable for motor ratings from 180 to 240 volts, or from 320 to 480 volts.

E. The Drive shall be able to operate after a voltage dip below 175 VAC on 230 VAC input power and 310 VAC on 480 VAC input power for 15 milliseconds at 85% full load current without any disturbances in output power delivered to the load.

F. The VFD output voltage shall vary with frequency to maintain a constant volts/hertz ratio up to base speed (60 hertz) output. Constant or linear voltage output shall be supplied at frequencies greater than base speed (60 hertz).

G. The VFD overload current rating shall be 110% of rated current for one minute for variable torque applications and 150% of rated current for constant torque applications, in an ambient temperature of 104ºF.

H. The VFD shall have an efficiency at full load and speed that exceeds 95% for VFDs below 15 HP and 97% for drives 15 HP and above. The efficiency shall exceed 90% at 50% speed and load.

I. The true power factor shall be 0.95 or better at any speed, measured at drive input terminals.

J. The voltage regulation shall be plus or minus 1 percent of rated value, no load to full load.

K. Output Frequency Drift shall be not more than plus or minus 0.5 percent from set point.

L. VFDs shall withstand five cycle transient voltage dips of up to 15 percent of rated voltage without an under voltage trip or fault shutdown, while operating a variable torque load.

M. Line notching, transients, and harmonics on the incoming line shall not affect drive performance.

N. The VFDs shall meet IEC 61200-2 for vibration levels.

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O. The VFDs shall be able to withstand voltage variations of -15% to +10% and imbalance up to 3% without tripping or affecting drive performance.

P. For additional requirements and construction notes, refer to the Drawings.

2.3 CONSTRUCTION


ratings of devices, components; protective relays, voltage ratings of devices, components and assemblies; and other required details.

2. Control units shall be arranged as shown on the Drawings. 3. Surge Protective Devices

a. Furnish where shown on the Drawings, or specified herein, a manufacturer provided and installed, a Low Voltage Surge protective Device (SPD), as specified in Section 16196 of these Specifications.

b. Connection to the switchgear shall be with a surge rated disconnect, mounted integral to the switchgear.

c. Except for VFD components, where the equipment contains a programmable logic controller (PLC) or an uninterruptible power supply (UPS), the equipment manufacturer shall furnish factory installed, a dedicated Point of Utilization Device (SPD), with disconnecting means, as specified in Section 16196, Individual Control Panel and Related Equipment Protection (Type 3).

4. Where Kirk-Key arrangements are used, the Kirk keyed interlocks shall be Kirk HD Series (Heavy Duty) 316 Series of 316 stainless steel, or approved equal.


1) Nameplates shall be engraved, laminated impact acrylic, matte finish, not less than 1/16-in thick by 3/4-in by 2-1/2-in, Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures except for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”, or equal. Prior to installing the nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residue has been removed. Epoxy adhesive or foam tape is not acceptable.

2) There shall be a master nameplate that indicates equipment ratings, manufacturer's name, shop order number and general information. Cubicle nameplates shall be mounted on the front face, on the rear panel and inside the assembly, visible when the rear panel is removed.

3) Provide permanent warning signs as follows: a) "Danger- High Voltage- Keep Out" on all doors. b) "Warning- Hazard of Electric Shock - Disconnect Power Before

Opening or Working On This Unit" on main power disconnect. b. Internal

1) Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification, corresponding to appropriate designations on manufacturer's wiring diagrams.




mounted on the panel door. All controls and indicators shall be 30mm, corrosion resistant, NEMA 4X/13, anodized aluminum or reinforced plastic. Booted control

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devices are not acceptable. Auxiliary contacts shall be provided for remote run indication and indication of each status and alarm condition. Additional controls shall be provided as specified herein and as required by the detailed mechanical and electrical equipment requirements.







g. Control and Instrument Power Transformers 1) Control power transformers shall be provided where shown on the Drawings.

Transformer shall be sized for the entire load, including space heaters, plus 25% spare capacity.

2) Control power transformers shall be 120 volt grounded secondary. Primary side of the transformer shall be fused in both legs. One leg of the transformer secondary shall be solidly grounded while the other leg shall be fused.

7. A failure alarm with horn and beacon light shall be provided when required or specified. Silence and Reset buttons shall be furnished. Alarm horn and beacon shall be by Federal Signal; Crouse-Hinds, or equal, NEMA 4X for all areas except for NEMA 7 areas, which shall be NEMA 7 cast aluminum.

8. Where specified or shown on the Drawings, a six digit, non-resettable elapsed time meter shall be installed on the face of each motor starter. Meter shall be as specified in Section 16195.

9. Each VFD shall have an HMCP or thermal magnetic circuit breaker, as shown on the Drawings, to provide a disconnect means. VFDs above 75HP shall have a solid state circuit breaker. Disconnecting means shall have a through the door lockable handle, mechanically interlocked with the enclosure door. The disconnect shall not be mounted on the door. The handle position shall indicate ON, OFF, and TRIPPED condition. The handle shall have provisions for padlocking in the OFF position with at least three (3) padlocks. Interlocks shall prevent unauthorized opening or closing of the VFD door with the disconnect handle in the ON position. Door handle interlock shall be defeatable only by qualified maintenance personnel.

10. Each VFD shall have the application specific, Hand-Off-Remote and Auto-Manual selector switches for local and remote Auto-Manual operation, provisions to accept a remote dry contact closure to start and stop the drive with the drive control system in the AUTO mode, provisions to accept a 4-20 mA dc input signal for remote speed control, and other input, output and communications interfaces as shown on the Drawings.

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Inputs shall be isolated at the drive and active with the drive control system in the AUTO mode.

11. Each VFD shall be microprocessor based with an LED and LCD display to monitor operating conditions. The Drive display section shall allow for local operation and setting of Drive function codes and display fault indication and reasons associated with the fault. The LED display shall offer nine (9) different display settings and the LCD shall have the capacity to display five (5) lines of information at a time. The keypad shall be capable of copying, uploading and downloading drive function codes. Displays and settings shall be as specified for each of the horsepower ranges of VFDs.

12. The VFD shall have an AC output contactor to provide a means for positive disconnection of the drive output from the motor terminals which shall open anytime the VFD is not providing power to the motor, because it was commanded to stop or tripped due to an internal or external initiated fault.








coat of weatherproof white paint. j. All enclosures shall be pad lockable.

2. The VFD shall be provided in a NEMA 12 rated enclosure with the following features: a. NEMA 12 Aluminum




C. Cooling Fans 1. Fans shall be furnished for VFDs, as required by the manufacturer, to provide air

circulation and cooling. The fan shall be controlled by a thermostat and shall operate only when the drive is “ON” and for a cool-down period after the drive has stopped. Otherwise the fan shall not run when the drive is “OFF”. Louvers, if provided, shall have externally removable filters. The filter shall be metallic and washable.

2. Fan motors shall be protected by an input circuit breaker or fuses.

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3. A “loss of cooling” fault shall be furnished. In the event of clogged filters or fan failure, the drive shall produce an alarm and then, in a predetermined time, shut down safely without electronic component failure.

D. Internal Wiring 1. Wiring: Tinned stranded copper, minimum size No. 14 AWG, with 600 Volt, 90-degree

C, flame retardant, Type MTW thermoplastic insulation, NEMA Class II, Type B wiring. Line side power wiring shall be sized for the full rating or frame size of the connected device.

2. Identification: Numbered sleeve type wire markers at each termination point, color coding per NEMA standards and the NEC. Foreign voltage control wiring shall be yellow.



E. Field Installed Internal Wiring 1. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie

wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring.


3. In general, all conduit entering or leaving equipment shall be stubbed up into the bottom of the enclosure directly below the area in which the conductors are to be terminated, or from the top if shown on the Drawings. Conduits shall not enter the side unless approved in writing by the Owner/Engineer.

F. Control Relays 1. Control relays shall be 300 volt, industrial rated, plug-in socket type, housed in a

transparent polycarbonate dust cover, designed in accordance with UL Standard 508 for motor controller duty. Continuous contact rating shall be 10 amperes resistive, ¼ HP at 120 VAC, operating temperature minus 10 to plus 55 degrees C. Provide spare N.O. & N.C. contacts. Relays shall be equipped with neon coil indicator light. Timing relays shall be 300 Volt, solid state type, with rotary switch to select the timing range. All relays provided in the equipment shall be NEMA rated. IEC rated relays are not acceptable.

2.4 ADJUSTABLE FREQUENCY DRIVES (VFDS) FOR MOTORS 60 HP AND SMALLER

A. General 1. Each VFD shall be a 6-pulse, Pulse Width Modulated (PWM) design converting the utility

input voltage and frequency to a variable voltage and frequency output via a two-step operation, designed for use with standard induction motors, constant or variable torque as required for the load application, with current limiting input fuses, incoming line reactors, circuit breaker disconnect, output contactor, control transformer overload relays and process signal follower card. Drives shall be UL listed. Adjustable frequency drives manufactured for HVAC applications are not acceptable. Adjustable Current Source VFDs are not acceptable. The output devices shall be Insulated Gate Bipolar Transistors (IGBTs). Bipolar Junction Transistors, GTOs or SCR’ are not acceptable.

2. The VFD shall have an EMI/RFI filter as standard. 3. Each VFD shall consist of the following general components:

a. Full wave diode rectifier to convert supply AC to a fixed DC voltage.

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b. DC link capacitors c. Insulated Gate Bipolar Transistor (IGBT) power section. The power section shall

use vector dispersal pulse width modulated (PWM) control and soft switching IGBTs.

d. Microprocessor based control and display section. 4. Each VFD shall, as a minimum, contain a 5% input line reactor, as standard. If harmonic

studies require 3% input reactor or a matrix filter to meet the specifications and applicable standards, the Contactor shall provide the additional harmonic mitigation equipment at no additional cost to the Owner.

5. The VFD shall be able to start into a spinning motor. The VFD 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 VFD 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.

6. The Drive shall maintain set frequency regardless of load fluctuations. 7. The Drive shall be able to operate after a voltage dip below 175 VAC on 230 VAC input

power and 310 VAC on 460 VAC input power for 15 milliseconds at 85% full load current without any disturbances in output power delivered to the load. If power exceeds this level, six (6) different modes or active and inactive restart modes shall be available. The decrease in motor speed shall be adjustable in the event of a momentary power outage.

8. The Drive shall have a programmable start frequency, adjustable from 0.1 to 60 hertz, with a 1 hertz resolution and with a holding time adjustable from 0.1 to 10 seconds.

9. The Drive shall have IGBT soft switching and a low noise control power supply system to reduce the noise from the drive.

10. The Drive shall have a frequency bias (starting frequency) function programmable from -120 to +120 Hz of maximum frequency, with 0.1 Hz resolution.

11. Drive frequency gain shall be programmable from 0-200%, with 0.1% resolution. 12. The Drive shall be capable of motor slowdown or stop by selectable regenerative (to the

DC link) dynamic braking while following one of the four selectable deceleration ramps, and control the braking torque by setting it’s value from 0, 20 to 150%, 999 (no limit) of Drive rating. It shall also be capable of changing the rate of deceleration automatically by stopping the braking action long enough to avoid Drive over-voltage trip.

13. The Drive shall be capable of starting into a rotating load (forward or reverse) and shall smoothly accelerate or decelerate to the set point without experiencing component damage.

14. The Drive shall be capable of stopping by selectable DC injection braking. It shall be adjustable from 0 to 100% braking level and have a programmable starting frequency for DC braking (0.2-60 hertz) and programmable braking time (0.1 to 30.0 seconds).

15. The Drive shall have a start Frequency Setting that incorporates a Holding Time at the Frequency Setting, adjustable up to 10 seconds in duration.

16. The Drive shall provide at least three selectable skip frequencies with programmable band widths, adjustable 0 to 30 Hz, which shall not allow operation at or near mechanical resonance speeds.

17. The Drive shall provide selectable slip compensation, which shall sense output current and adjust output

18. The Drive shall have Droop operation, balancing drooping characteristics to speed and load variations. This function shall be adjustable from –9.9 to 0.0 Hz.

19. The Drive shall have a selectable Torque Limiting function for both motoring and braking that shall sense an overload condition and shall reduce frequency and current temporarily until the load reaches acceptable levels. If the overload condition is not settled in the proper amount of time, the Drive shall trip on overload. The Torque Limiting shall be programmable from 20-150% of Drive rated motor torque (30 HP an below) and from 20-150% of Drive rated motor torque (40 HP and above), with 1% resolution.

20. The Drive shall have a selectable electronic inverse time thermal overload function as required by NEC and UL Standard 991 for an AC Induction Motor (Refer to applicable

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codes for specific installation requirements). The overload shall be programmable from 20 - 135% of Drive rated current.

21. The Drive shall have an over-voltage protection function that operates if supply voltage rises above rated value or by motor’s regeneration.

22. The Drive shall treat short circuits in either the output load or the output module as an over-current.

23. If the Drive heat sink temperature exceeds approximately 100o C, the Drive shall shut down on over temperature fault.

24. The Drive shall provide output ground fault protection.

B. Control and Monitor Interface 1. The Control shall have a graphic back-lit liquid crystal display (LCD) which can be

configured to display frequency, current, function code set points, or drive status and fault codes. It shall display lines with characters of text, providing display at a minimum of: a. Monitor b. Operate c. Parameter setup d. Actual parameter values e. Active faults f. Fault history g. LCD adjustments

2. Setups and Adjustments a. Start command from keypad, remote or communications port b. Speed command from keypad, remote or communications port c. Motor direction selection d. Maximum and minimum speed limits e. Acceleration and deceleration times, two settable ranges f. Critical (skip) frequency avoidance g. Torque limit h. Multiple attempt restart function i. Multiple preset speeds adjustment j. Catch a spinning motor start or normal start selection k. Programmable analog output l. DC brake current magnitude and time m. PID process controller

3. System Interfaces a. Remote manual/auto b. Remote start/stop c. Remote forward/reverse d. Remote preset speeds e. Remote external trip f. Remote fault reset g. Process control speed reference interface, 4-20mA DC h. Potentiometer and 1-10VDC speed reference interface i. Two RS-485 programming and operation interface ports

C. Outputs – A minimum of two (2) discrete programmable digital outputs, one (1) programmable open collector output, and one (1) programmable analog output 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

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e. Jogging f. At speed g. Torque Limit Supervision h. Motor rotation direction opposite of commanded i. Over-temperature

2. Programmable open collector output with available 24VDC power supply and 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

3. Programmable analog output signal, selectable with the following available at minimum: a. Motor current b. Output frequency c. Frequency reference d. Motor speed e. Motor torque f. Motor power g. Motor voltage h. DC-bus voltage i. AI1 (Analog Input 1) j. AI2 (Analog Input 2)

2.5 ADJUSTABLE FREQUENCY DRIVES (VFDS) FOR MOTORS LARGER THAN 60 HP

A. General 1. Each drive shall be a minimum 18-pulse, IGBT based sinusoidal PWM type AC Drive

capable of operating a squirrel cage induction motor with a full load current equal to or less than the continuous output of the Drive. The drive panel shall incorporate a phase shift transformer and a minimum 18 pulse converter. Regulator technology shall be software configurable to either V/Hz (single or multi motor) mode or Sensorless Dynamic Torque Vector mode (single motor). Full, closed loop flux vector control shall be available for constant torque applications. In V/Hz mode at base speed (60 hertz) and below, the Drive shall operate in constant volts per hertz mode. Above base speed (60 hertz), the Drive may selectively operate in either a constant volt per hertz mode or a constant voltage extended frequency mode.

2. The VFD shall be able to start into a spinning motor. The VFD 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 VFD 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.

3. The Drive shall maintain set frequency regardless of load fluctuations. 4. The Drive shall be able to operate after a voltage dip below 175 VAC on 230 VAC input

power and 310 VAC on 460 VAC input power for 15 milliseconds at 85% full load current without any disturbances in output power delivered to the load. If power exceeds this level, six (6) different modes or active and inactive restart modes shall be available. The decrease in motor speed shall be adjustable in the event of a momentary power outage.

5. The Drive shall have a programmable start frequency, adjustable from 0.1 to 60 hertz, with a 1 hertz resolution and with a holding time adjustable from 0.1 to 10 seconds.

6. The Drive shall have IGBT soft switching and a low noise control power supply system to reduce the noise from the drive.

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7. The Drive shall have a frequency bias (starting frequency) function programmable from -120 to +120 Hz of maximum frequency, with 0.1 Hz resolution.

8. Drive frequency gain shall be programmable from 0-200%, with 0.1% resolution. 9. The Drive shall be capable of motor slowdown or stop by selectable regenerative (to the

DC link) dynamic braking while following one of the four selectable deceleration ramps, and control the braking torque by setting its value from 0, 20 to 150%, 999 (no limit) of Drive rating. It shall also be capable of changing the rate of deceleration automatically by stopping the braking action long enough to avoid Drive over-voltage trip.

10. The Drive shall be capable of starting into a rotating load (forward or reverse) and shall smoothly accelerate or decelerate to the set point without experiencing component damage.

11. The Drive shall be capable of stopping by selectable DC injection braking. It shall be adjustable from 0 to 100% braking level and have a programmable starting frequency for DC braking (0.2-60 hertz) and programmable braking time (0.1 to 30.0 seconds).

12. The Drive shall have a start Frequency Setting that incorporates a Holding Time at the Frequency Setting, adjustable up to 10 seconds in duration.

13. The Drive shall provide at least three selectable skip frequencies with programmable band widths, adjustable 0 to 30 Hz, which shall not allow operation at or near mechanical resonance speeds.

14. The Drive shall provide selectable slip compensation, which shall sense output current and adjust output

15. The Drive shall have Droop operation, balancing drooping characteristics to speed and load variations. This function shall be adjustable from –9.9 to 0.0 Hz.

16. The Drive shall have a selectable Torque Limiting function for both motoring and braking that shall sense an overload condition and shall reduce frequency and current temporarily until the load reaches acceptable levels. If the overload condition is not settled in the proper amount of time, the Drive shall trip on overload. The Torque Limiting shall be programmable from 20-150% of Drive rated motor torque (30 HP an below) and from 20-150% of Drive rated motor torque (40 HP and above), with 1% resolution.

17. The Drive shall have a selectable electronic inverse time thermal overload function as required by NEC and UL Standard 991 for an AC Induction Motor (Refer to applicable codes for specific installation requirements). The overload shall be programmable from 20 - 135% of Drive rated current.

18. The Drive shall have an over-voltage protection function that operates if supply voltage rises above rated value or by motor’s regeneration.

19. The Drive shall treat short circuits in either the output load or the output module as an over-current.

20. If the Drive heat sink temperature exceeds approximately 100º C, the Drive shall shut down on over temperature fault.

21. The Drive shall provide output ground fault protection.

B. Control and Monitor Interface 1. The Control shall have a graphic back-lit liquid crystal display (LCD) which can be

configured to display frequency, current, function code set points, or drive status and fault codes. It shall display lines with characters of text, providing display at a minimum of: a. Monitor b. Operate c. Parameter setup d. Actual parameter values e. Active faults f. Fault history g. LCD adjustments

2. Setups and Adjustments a. Start command from keypad, remote or communications port b. Speed command from keypad, remote or communications port

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c. Motor direction selection d. Maximum and minimum speed limits e. Acceleration and deceleration times, two settable ranges f. Critical (skip) frequency avoidance g. Torque limit h. Multiple attempt restart function i. Multiple preset speeds adjustment j. Catch a spinning motor start or normal start selection k. Programmable analog output l. DC brake current magnitude and time m. PID process controller

3. System Interfaces a. Remote manual/auto b. Remote start/stop c. Remote forward/reverse d. Remote preset speeds e. Remote external trip f. Remote fault reset g. Process control speed reference interface, 4-20mA DC h. Potentiometer and 1-10VDC speed reference interface i. Programming interface port.

C. Outputs – A minimum of two (2) discrete programmable digital outputs, one (1) programmable open collector output, and one (1) programmable analog output 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 open collector output with available 24VDC power supply and 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

3. Programmable analog output signal, selectable with the following available at minimum: a. Motor current b. Output frequency c. Frequency reference d. Motor speed e. Motor torque f. Motor power g. Motor voltage h. DC-bus voltage

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i. AI1 (Analog Input 1) j. AI2 (Analog Input 2)


A. General: All control and interconnection points from the equipment to the plant control and monitoring system shall be brought to a separate connection box. No field connections shall be made directly to the equipment control devices. Functions to be brought out shall be as specified in the Instrumentation Divisions.




E. Refer to the Instrumentation Divisions for monitored parameters.




2. The protocol interface shall implement the following: a. All data shall be available and/or mirrored within the Modbus 4x or "Holding


tests". 3. The media protocol converter shall meet the following criteria:





2.7 SPARE PARTS

A. Provide the following spare parts: 1. 3 – Control fuses of type used. 2. 3 – Power fuses of type used.


2.8 FACTORY TESTING

A. The VFDs shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer’s routine shop tests and any other additional operational test to insure the workability and reliable operation of the equipment.

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B. Prior to factory testing, the manufacturer shall check to see that all selections and settings required by the Power System Study Engineer have been performed.

C. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards.

D. The operational test shall include the proper connection of supply and control voltage and, as far as practical, a mockup of simulated control signals and control devices shall be fed into the boards to check for proper operation.

PART 3 - EXECUTION


A. Provide the services of a qualified factory-trained manufacturer's field engineer to assist the Contractor in installation and start-up of each type of the equipment specified below for a period of not less than 2 working days, with not less than one working day per VFD. The manufacturer's field engineer 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.


A. Installer shall be specialized in installing low voltage adjustable frequency drives with minimum 5 years documented experience. Experience documentation shall be submitted for approval prior to beginning work on this project.

3.3 EXAMINATION






3.4 INSTALLATION






3.6 FIELD ADJUSTING


B. The Power Monitoring and Protective Relays shall be set in the field by a qualified representative of the manufacturer, retained by the Contractor, in accordance with settings

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designated in a coordinated study of the system as required in Section 16105 Power System Study. All such settings, including the application of arc flash labels, shall have been made and Approved by the Owner/Engineer, prior to energizing of the equipment.

3.7 FIELD TESTING

A. The VFD manufacturer’s field engineer shall perform all electrical field tests recommended by the manufacturer, and make all control adjustments required for the individual application of the drive.

3.8 CLEANING







3.11 TRAINING

A. Provide manufacturer's services for training of plant personnel in operation and maintenance of the adjustable frequency drives furnished under this Section.

B. The training for each type of equipment shall be for a period of not less than one (1) eight hour day.





END OF SECTION

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MECHANICAL EQUIPMENT MANUFACTURER’S PROVIDED CONTROL PANELS (MEMS) Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16486 MECHANICAL EQUIPMENT MANUFACTURER'S PROVIDED CONTROL PANELS (MEMS).DOCX

SECTION 16486 MECHANICAL EQUIPMENT MANUFACTURER’S PROVIDED CONTROL PANELS (MEMs)

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish and install functional control panels to manually or automatically operate control systems as specified in the detailed requirements of this Section, and as described in the Process Equipment Division Specifications.

B. All submittals for, process equipment panels specified under this Section, shall be submitted as a part of the Process Equipment manufacturer’s submittal under the Process Equipment Division submittals.

1.2 RELATED WORK



C. Section 16196 Low Voltage Surge Protective Devices (SPDs)

D. Section 13327 Panel Mounted Control Devices

E. Section 16033 Cast-In-Place Concrete for Electrical Applications

F. Section 16105 Power System Study

G. Section 13500 Programmable Logic Controller (PLC) Systems

H. Section 13505 Operation Interface Terminal (OIT)

I. Process Equipment Division 11 Specifications

J. Instrumentation Equipment Division 17 Specifications

K. Mechanical Equipment Division 15 Specifications

L. The Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

M. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of Division 1, Process Equipment Division and as specified herein.

B. Provide systems engineering to produce coordination curves, showing coordination between existing and new breakers and/or fuses submitted, such that protective device coordination is accomplished. Such curves and settings shall be included as a part of these submittals.

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C. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will also be returned un-reviewed.

D. The mechanical equipment manufacturer shall create all equipment shop drawings, including all wiring diagrams, in the manufacturer’s Engineering department. All equipment shop drawings shall bear the mechanical equipment manufacturer’s logo, drawing file numbers, and shall be maintained on file in the mechanical equipment manufacturer’s archive file system.

E. Submit to the Owner/Engineer, shop drawings and product data, for the following: 1. The mechanical equipment manufacturer shall use his control systems engineering

department to produce custom unit elementary drawings. Drawings shall be on the mechanical equipment manufacturer’s drawing sheets, and shall include all schematics for control logic as described in the Process Equipment Specifications, and any associated control schematics shown on the Engineer’s Drawings for this project. Show internal and external wiring and interlocking between components and to remotely mounted devices. Include and identify all connecting equipment and remote devices on the schematics. The notation “Remote Device” will not be acceptable. Show wire and terminal numbers. Indicate special identifications for devices as required by the mechanical equipment manufacturer or as may be shown on the Drawings.

2. Equipment outline drawings showing elevation, plan and interior views, front panel arrangement, dimensions, weight, shipping splits, conduit entrances and anchor bolt pattern. Indicate all options, special features, ratings and deviations from this Section.

3. Power and control schematics including external connections. Show wire and terminal numbers and color-coding.

4. Instruction and replacement parts books, including manufacturer’s part numbers, selections of component ratings, and CT and PT ratios.

5. As-built final drawings. 6. Documentation that the panel assembly facility is a UL-508 certified facility. 7. Facsimile of the UL label that is to be applied to the completed panel. 8. Furnish complete Bill of Materials indicating manufacturer's name and part numbers. 9. Manufacturer’s cut sheets for every component used in the panel assembly adequately

marked to show the items being included. The manufacturer’s name shall be clearly visible on each cut sheet submitted.

10. Assembly ratings including: a. Short-circuit rating b. Voltage c. Continuous current

11. 11. Major component ratings including: a. Voltage b. Continuous current c. Interrupting ratings

12. Cable terminal sizes. 13. Instruction and renewal parts books.

F. Factory Tests. Submittals shall be made for factory tests specified herein.


H. Operation and Maintenance Manuals. 1. Operation and Maintenance Manuals shall include the following information:


above.

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I. The manufacturer shall submit for approval, a training agenda for all training specified herein. Training agenda shall not be submitted until final approval of the Operation and Maintenance Manual.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA Standard ICS 2 – 2000 Industrial Control and Systems 2. NFPA 70 – National Electrical Code (NEC) 3. NFPA 70E – Standard For Electrical Safety in the Workplace 4. NFPA 79 – Electrical Standard for Industrial Machinery 5. UL 508/508A – Industrial Control Enclosures



A. The manufacturer of the control panels shall have produced similar 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.

B. The control panels shall be assembled in a UL-508 certified facility. A submittal of documentation certifying that the panel fabrication facility is a UL-508 certified facility, is required. A UL label shall be affixed to the inside of the external door by the panel fabrication assembly. Submit a facsimile of the UL label in the submittal information.


D. Control panels submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.






D. Equipment shall be installed in its permanent finished location shown on the Drawings within seven calendar days of arriving onsite. If the equipment cannot be installed within seven calendar days, the equipment shall not be delivered to the site, but stored offsite, at the Contractor’s expense, until such time that the site is ready for permanent installation of the equipment.

E. Where space heaters are provided in equipment, provide temporary electrical power and operate space heaters during storage, and after equipment is installed in permanent location, until equipment is placed in service.

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1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for the same length of time as the associated mechanical equipment, but not less than 1 year from date of final acceptance of the equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work, requiring shipping or transporting of the equipment, shall be performed by the Manufacturer, at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MATERIAL MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Material Manufacturers are acceptable: 1. General Electric Co. 2. Eaton / Cutler-Hammer 3. Square D Co. 4. Allen Bradley

B. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Materials listed above are not relieved from meeting these Specifications in their entirety.

C. The mechanical equipment manufacturer shall be responsible for providing all required controls and apparatus as specified utilizing the specified components herein.

2.2 RATINGS

A. The service voltage shall be as specified and as shown on the Drawings. The overall short circuit withstand and interrupting rating of the equipment and devices shall be not less than 22,000 amperes RMS symmetrical at 480/277 Volts, and equal to or greater than the overall short circuit withstand and interrupting rating of the feeder device immediately upstream of the Control Panel. This includes all circuit breakers and combination motor starters. Systems of motor controllers employing series connected ratings for main and feeder devices shall not be used. Motor starter units shall be tested and UL 508A labeled for the specified short circuit duty in combination with the motor branch circuit protective device.

B. There shall be selective device coordination between the Main Breaker, Feeder Breakers and control circuit protective devices. When using a circuit breaker or fuses as a main protective device, the instantaneous trip levels of the main protective device shall be higher than the available fault current to the control panel. If fuses are utilized in the control panel design, the protective devices for 3 phase loads shall contain single phase protection of such equipment. If a fault occurs in the circuit of one load of a design with a backup load, the feeder protective device shall not remove both loads from the control system.

C. Use ground fault sensing on grounded wye systems.

D. The complete control panel assembly shall be UL certified and carry a UL listing for "Industrial Control Panels".

E. The control panel shall meet all applicable requirements of the National Electrical Code.

F. The control panel enclosure shall be NEMA rated as specified herein.

G. Motor controllers, including associated devices, shall be designed for continuous operation at rated current in a 40 degree C ambient temperature.

H. For additional ratings and construction notes, refer to the mechanical equipment specifications and the Drawings.

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I. The Manufacturer shall produce and install on each panel, an Arc Flash Warning Label listing the various Flash Hazard Protection Boundaries, calculated from NFPA 70E, Annexes, as listed below: 1. Flash Hazard Protection Boundary. 2. Limited Approach Boundary. 3. Restricted Boundary. 4. Prohibited Boundary. 5. Incident Energy Level. 6. Required Personal Protective Equipment Class. 7. Type of Fire Rated Clothing.

J. Provide an Arc Flash Warning Label, printed in color and affixed to the front of each panel provided. Secure the required information from the Engineering Firm providing the study, as specified in Section 16105.

K. Shown below is a typical label. Size of each label shall be not less than 8 inches wide and 6 inches tall.

2.3 CONSTRUCTION

A. General 1. Submit actual layout and location of equipment and components; current ratings of

devices, bus bars, components; protective relays, voltage ratings of devices, components and assemblies; and other required details. NEMA ratings of all devices shall meet or exceed the rating of each panel.

2. Control units shall be arranged as shown on the Drawings. 3. Except for VFD components, where the equipment contains a programmable logic

controller (PLC) or a uninterruptible power supply (UPS), the equipment manufacturer shall furnish factory installed, a dedicated Point of Utilization Device (SPD), as specified in Section 16196, Individual Control Panel and Related Equipment Protection (Type 3).

4. Where Kirk-Key arrangements are used, the Kirk keyed interlocks shall be Kirk HD (Heavy Duty) 316 Series of 316 stainless steel, or approved equal.

5. Nameplates a. Exterior

1) Nameplates shall be engraved, laminated impact acrylic, matte finish, not less than 1/16-in thick by 3/4-in by 2-1/2-in, Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures except for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½”, or equal. Prior to installing the adhesive nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residues have been removed. Epoxy adhesive or foam tape is not acceptable.

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2) There shall be a master nameplate that indicates supply voltage equipment ratings, short circuit current rating, manufacturer's name, shop order number and general information. Cubicle nameplates shall be mounted on the front face, on the rear panel and inside the assembly, visible when the rear panel is removed.

3) Provide permanent warning signs as follows: a) "Danger- High Voltage- Keep Out" on all doors. b) "Warning- Hazard of Electric Shock - Disconnect Power Before

Opening or Working On This Unit" on Main Power Disconnect or Disconnects.

b. Internal 1) Provide the panel with a UL 508A label. 2) Control components mounted within the assembly, such as fuse blocks,







c. Mode selector switches (HAND-OFF-AUTO, LOCAL-OFF-REMOTE, etc shall have the number of positions and contact arrangements, as required. Each switch shall have an extra dry contact for remote monitoring.

d. Pushbuttons shall be as follows: 1) Red for STOP, Valve OPEN, Breaker CLOSE and mushroom Red for

EMERGENCY STOP. 2) Green for START, Valve CLOSE and Breaker OPEN. 3) Black for RESET.



g. Control and Instrument Power Transformers 1) Control power transformers shall be provided. Transformer shall be sized for

the entire load, including space heaters, plus 25% spare capacity, and shall be not less than 100VA.

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2) Control power transformers shall be 120 volt grounded secondary. Primary side of the transformer shall be fused in both legs. One leg of the transformer secondary shall be solidly grounded and the other leg shall be fused.

7. A failure alarm with horn and beacon light shall be provided when required or specified. Silence and Reset buttons shall be furnished. Alarm horn and beacon shall be by Federal Signal; Crouse-Hinds, or equal, NEMA 4X for all areas except for NEMA 7 areas, which shall be NEMA 7/4X cast aluminum.








coat of weatherproof white paint. j. All enclosures shall be able to be padlocked.



b. Manufacturers 1) Cooper Crouse Hinds Type EJB, Style C 2) Appleton Electric Type AJBEW 3) Approved Equal



b. Manufacturers 1) Hoffman Polypro 2) Hubbell-Wiegmann Non-Metallic 3) Approved Equal



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5. NEMA 12 a. NEMA 12 Aluminum



6. Otherwise Not Defined NEMA 4X Stainless Steel a. Where an enclosure is not otherwise defined or shown on the Drawing

1) NEMA 4X 316 Stainless Steel 2) Type 316 stainless steel, body and door 3) Stainless steel continuous hinge 4) Foam in-place gasket 5) Single point quarter turn latches (20”x24” and below). All others 3-point latch

b. Manufacturers 1) Hoffman Comline Series 2) EMF Company 3) NEMA Enclosures Company 4) Hammond Company 5) Approved Equal


C. Environmental Conditioning 1. Condensation Control

a. A self-contained enclosure condensation heater with thermostat and fan shall be mounted inside the control panel, if panel is mounted outdoors or in a non-air-conditioned space. 1) Enclosure heaters shall be energized from 120 volt, single-phase power

supply and sized to prevent condensation within the enclosure. 2) Locate enclosure heaters to avoid overheating electronic hardware or

producing large temperature fluctuations on the hardware. 3) Enclosure heaters shall have an internal fan for heat distribution and shall

be controlled with adjustable thermostats. The thermostat shall have an adjustment range of 40 degrees Fahrenheit to 90 degrees Fahrenheit. Provide a circuit breaker or fused disconnect switch within the enclosure.

4) Enclosure heaters shall be Hoffman type DAH or equal. b. Strip heaters may be provided if they are 240 volt rated, powered at 120 volts AC

and do not have a surface temperature higher than 60°C. Strip heaters and thermostats shall be as manufactured by Chromalox or equal. 1) Strip heaters shall be Chromalox, Type OT, 1.5-in wide, 240 Volts, single

phase, 150 watts, energized at 120 volts, with rust resisting iron sheath, Catalog No. OT-715, Product Code No. 129314, or equal. Provide sufficient wattage in heaters to prevent condensation should the interior temperature of the enclosure drop below the dew point.

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2) A control thermostat mounted inside the control Panel shall be Chromalox, Type WR, single stage, Catalog No. WR-80, Product Code No.263177, or equal.

3) The strip heater terminals shall be guarded by a protective terminal cover. 4) High temperature connecting lead wire shall be used between the

thermostat and the heater terminals. Wire shall be No. 12 AWG stranded, nickel-plated copper with Teflon glass insulation and shall be the product of Chromalox, Catalog No. 6-CFI-12, Product Code No. 263783, or equal.

c. Each panel shall have a ½” stainless steel condensate drain, installed on a stainless steel conduit hub, HGTZ Series, T&B or equal, in the bottom of the enclosure. Drain shall be O-Z Gedney DBB-50SS, or equal.

2. Corrosion Control a. Provide corrosion protection in each control panel with a corrosion-Inhibiting vapor

capsule as manufactured by Northern Instruments; Model Zerust VC, or Hoffman Engineering; Model A-HCI, or equal.

3. Panel Interior Ambient Control a. The manufacturer shall provide ambient temperature control within the panel to

maintain internal temperatures below the maximum operating temperatures of the panel components. an ambient temperature range of -20° C to 40°C.

b. The manufacturer shall provide panel internal heat rise calculations to show that the panel internal temperatures will be maintained below the maximum operating temperatures of the panel components.

c. The calculation shall show all the internal and external heat gain loads, the expected internal temperature rise in degrees C above the specified ambient, If the specified temperature range cannot be met, an air conditioning system shall be provided with sufficient capacity to maintain the temperature within the specified limits. Panels, for which the calculated heat rise exceeds 40° C., shall have an air conditioning system, sized as required to reduce the heat rise to 40° C. or less, without violating the NEMA rating of the enclosure.

d. The air conditioner shall have the following features: 1) Use CFC-free R134a refrigerant. 2) Have fully gasketed flanges on all four mounting edges for a watertight seal

that maintains NEMA 4X rating of the panel. 3) Thermostatic low temperature control to provide energy efficient operation

and prevents over-cooling. 4) EMI/RFI suppressor to minimize transient spikes during compressor on/off

cycling. 5) Separated blower-driven evaporator and condenser air systems for closed

loop cooling. 6) UL listed. 7) Stainless steel enclosure. 8) Internal corrosion resistant coating. 9) Low ambient kit. 10) Short cycle protector. 11) The air conditioning unit shall be Hoffman, Thermo Electric or approved

equal. 4. Enclosure Fans

a. Fans shall be furnished for soft start starters and VFDs, as required by the manufacturer, to provide air circulation and cooling. Fans shall be controlled by a temperature switch. The fan shall operate only when the drive is “ON” and for a cool-down period after the drive has stopped Otherwise the fan shall not run when the drive is “OFF”. Louvers, if provided, shall have externally removable filters. The filter shall be metallic and washable.

b. Fan motors shall be protected by an input circuit breaker. Metal squirrel cage ball bearing, three phase fan motors with 10-year design life shall be used in the drive

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design. Plastic muffin fans are not acceptable. Fan power shall be obtained from a tap on the main control power transformer.

c. A “loss of cooling” fault shall be furnished. In the event of clogged filters or fan failure, the drive shall produce an alarm and then, in a predetermined time, be shut down safely without electronic component failure by the temperature switch.

d. Redundant fans shall be provided in the drive design as backup in the event of fan failure.

D. Internal Wiring 1. Power and control wiring shall be tinned stranded copper, minimum size No. 14 AWG,

with 600 Volt, 90 degree C, flame retardant, Type MTW thermoplastic insulation. Line side power wiring shall be sized for the full rating or frame size of the connected device.

2. Analog signal wires shall be 600 Volt Class, insulated stranded tinned copper, twisted shielded #16 AWG pair.

3. All interconnecting wires between panel mounted equipment and external equipment shall be terminated at numbered terminal blocks. Field wiring shall not be terminated directly on any panel-mounted device.


5. All wiring shall be enclosed in PVC wire trough with slotted side openings and removable cover. Plan wire routing such that no low twisted shielded pair cable conducting analog 4-20 mA signals or low voltage analog signals are routed in the same wire trough as conductors carrying discrete signals or power.

6. All control panel wiring shall use the following color code. a. Black: AC power at line voltage b. Red: switched AC power c. Orange: May be energized while the main disconnect is in the off position d. White: AC neutral e. Orange/white stripe or white/orange stripe: separate derived neutral f. Red/white stripe or white/red stripe: switched neutral g. Green or green w/ yellow tracer: ground/earth ground h. Blue: Ungrounded DC power i. Blue/white stripe or white/blue stripe: DC grounded common j. Brown: 480V AC 3 phase - phase A k. Orange: 480V AC 3 phase - phase B l. Yellow: 480V AC 3 Phase - phase C m. Purple: common for analog signal wiring n. Brown: positive leg of an analog signal

E. Field Installed Internal Wiring 1. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie

wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring.


3. In general, all conduit entering or leaving equipment shall be stubbed up into the bottom of the enclosure directly below the area in which the conductors are to be terminated. Conduits shall not enter the side unless approved in writing by the Owner/Engineer.

F. Terminal Blocks 1. Terminal blocks shall be DIN-rail-mounted one-piece molded plastic blocks with tubular-

clamp-screw type and end barriers. Terminal blocks shall be rated for 600 volts except for control and instrumentation circuits, or 4-20 mA analog signal conductors.

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2. Provide 600 volt rated terminal blocks for any conductor carrying any voltage over 120 volts to ground.




6. Use the manufacturer’s provided bridge connectors to interconnect terminal blocks terminating common or ground conductors.


8. Control circuits, 120 volts and below, and 4-20 mA analog signal conductors shall be terminated with manufacturer’s recommended insulated connectors.

9. Provide an AC ground bar bonded to the panel enclosure (if metal) with 20 percent spare terminals.


2.4 SERVICE ENTRANCE DEVICE

A. Where the Control Panel is rated and used as a service entrance panel, the manufacturer shall furnish factory installed in the Control Panel, a dedicated (SPD) (Type 2), permanently connected, Surge Protective Device on the load side of the service entrance device, as specified in Section 16196 Low Voltage AC Surge Protective Devices (SPDs).

2.5 MAIN CIRCUIT PROTECTIVE DEVICE

A. Unless otherwise shown on the Drawings, the main circuit protective device shall be a molded case (MCCB), 3 Pole, 600 Volt, fixed type, manually operated with stored energy closing mechanism. Trip device shall be solid state with adjustable long time pickup, and delay; adjustable short time pickup and delay; short time i2t switch, adjustable ground fault pickup and delay, and ground fault delay and pickup trips for selective tripping.

B. Provide a flange mounted main power disconnect operating handle with mechanical interlock having a bypass that will allow the panel door to open only when the switch is in the OFF position. Where panels are shown or specified with inner and outer doors, disconnecting handles and controls shall be located on the inner door.


A. General 1. Provide the NEMA size starter, circuit breaker trip ratings, control power transformers

and thermal overload heater element ratings matched to the motors and control equipment actually supplied, in compliance with the NEC and the manufacturer’s heater selection tables. All variations necessary to accommodate the motors and controls as actually furnished shall be made without extra cost to the Owner.

2. Furnish lugs for incoming wiring. Allow adequate clearance for bending and terminating of cable size and type specified.

3. A NEMA rated magnetic motor starter shall be furnished for each motor. Each motor starter shall be provided with a motor circuit protector, or circuit breaker, and equipped to provide under voltage release and overload protection on all three phases. The short

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circuit protective device shall have an adjustable magnetic trip range up to 1400 percent of rated continuous current and a trip test feature. MCPs shall be labeled in accordance with UL489. NEMA starter sizes and breaker trip ratings shall be as required for the horsepower indicated, but shall be in no case less than NEMA Size 1. If the manufacturer of the equipment utilizing the motor, supplies a motor horsepower larger than that shown on the Drawings, the Contractor shall supply a motor starter sufficient in size to control the motor supplied.

4. A mechanical disconnect mechanism, with bypass, shall be installed on each motor circuit protector, capable of being locked in the "OFF" position to provide a means of disconnecting power to each motor. Disconnects mechanisms shall be located inside the enclosure such that the main circuit breaker handle is the only device interlocked with the panel door.

5. Each motor starter shall have a 120 volt operating coil unless otherwise noted. 6. Overload relays shall be standard Class 20, ambient compensated, manually reset by

pushbutton located on front of the starter door. A normally closed contact shall be directly used in the start circuit and a normally open contact shall be wire to a terminal board for overload alarm.

7. All interfaces between control panel and remote devices shall be isolated via an interposing relay. Interposing relays shall have contacts rated for 250 VAC and 10 Amps continuous. Relays shall be Control Relays as specified herein.


magnetically operated, full voltage non reversing. NEMA sizes shall be as required for the horsepower shown on the Drawings.

2. Each motor starter shall have a 120 volt operating coil, and control power transformer. Starters shall have motor overload protection in each phase. Auxiliary contacts shall be provided as shown on the Drawings. A minimum of one N.O. and one N.C. auxiliary contacts shall be provided in addition to the contacts required.


Drawings. 5. All wires shall be terminated on terminal blocks and shall be tagged. 6. Provide as built wiring diagram and post it in a protective cover inside the cell.

C. Contactors 1. Contactors shall be a circuit breaker and contactor, 600 Volt, 3 Pole, 60 Hz, magnetically

operated. NEMA size shall be as required for the kilowatt ratings required for the equipment provided, but shall be not less than NEMA size 1.

2. Contactors shall have a 120 Volt operating coil and control power transformer. Furnish the control power transformer with extra capacity for the unit heater fan.

D. Control Relays 1. Control relays shall be 300 volt, industrial rated, plug-in socket type, housed in a

transparent polycarbonate dust cover, designed in accordance with UL Standard 508 for motor controller duty. Continuous contact rating shall be 10 amperes resistive, ¼ HP at 120 VAC, operating temperature minus 10 to plus 55 degrees C. Provide spare N.O. & N.C. contacts. Relays shall be Potter & Brumfield KRP Series or equal with neon coil indicator light. Timing relays shall be 300 Volt, solid state type, with rotary switch to select the timing range.

E. Elapsed Time Meter 1. A six digit, non-resettable elapsed time meter shall be installed on the face of each motor

starter. Meter shall be as specified in Section 16195.

2.7 LOGIC DEVICES

A. Programmable Logic Controller

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1. Where the control panel contains a programmable logic controller (PLC) for programming of the control logic, the manufacturer shall provide the address list, and an Ethernet interface to connect to the Owner’s plant monitoring system for monitoring of the PLC’s operation.

2. Provide a fully documented and scripted program file for each PLC.

B. Operator Interface Terminal 1. Where the control panel contains an Operation Interface Terminal for interfacing to the

control logic, the manufacturer shall provide the address list, and an Ethernet and serial interface to connect to the related PLC for monitoring and control of the PLCs operation.

2. Provide a scripted application and fully documented setup for each OIT.

2.8 INSTRUMENTATION DEVICES

A. Level Switches 1. Where Level Switches are specified or shown on the Drawings, refer to the

Instrumentation Division for the required devices.

B. Programmable Logic Controllers (PLCs) 1. Where PLCs are specified herein or shown on the Drawings, refer to the Instrumentation

Division for the required devices.

C. Operator Interface Terminals (OITs) 1. Where OITs are specified herein or shown on the Drawings, refer to the Instrumentation

Divisions for the required devices.


A. General: All control and interconnection points from the equipment to the plant control and monitoring system shall be brought to a separate connection box. No field connections shall be made directly to the equipment control devices. Functions to be brought out shall be as specified in the Instrumentation Divisions.




E. Refer to the Instrumentation Divisions for monitored parameters.




2. For projects using Modbus TCP protocol use the following protocol interface which shall implement the following: a. All data shall be available and/or mirrored within the Modbus 4x or "Holding


tests". c. Software tools shall function properly with slaves’ only supporting Modbus

functions 3, 4 and 16. Requiring support of diagnostic function 8 is not acceptable.

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d. Software tools shall be configurable to write a single register as either function 6 or 16.

e. Software tools shall allow setting the Modbus/TCP "Unit Id" to be a value other than zero. This is required for Ethernet-to-Serial bridging.

3. For projects using Ethernet/IP protocol use the following protocol interface which shall implement the following: a. Transfer of basic I/O data via User Datagram Protocol (UDP)-based implicit

messaging b. Uploading and downloading of parameters, set points, programs and recipes via

TCP (i.e., explicit messaging.) c. Polled, cyclic and change-of-state monitoring via UDP, such as RPI and COS in

Allen Bradley's ControlLogix control systems. d. One-to-one (unicast), one-to-many (multicast), and one-to-all (broadcast)

communication via TCP e. Use of well-known TCP port number 44818 for explicit messaging and UDP port

number 2222 for implicit messaging. 4. The media protocol converter shall meet the following criteria:





2.10 SPARE PARTS

A. Provide the following spare parts for each control panel in the quantities specified: 1. Six replacement fuses, all types and sizes 2. One replacement lamp, of each color, for pilot lights 3. One of each color replacement lens caps for pilot lights 4. One starter coil for each NEMA size furnished 5. One, 3-pole set of replacement overload heaters of each size range used 6. One, 3-pole set of starter contacts of each NEMA size used. 7. One can of aerosol touch-up paint.


2.11 FACTORY TESTING

A. The entire control panel shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer’s routine shop tests and any other additional operational test to insure the workability and reliable operation of the equipment.

B. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards.

C. The operational test shall include the proper connection of supply and control voltage and, as far as practical, a mockup of simulated control signals and control devices shall be fed into the boards to check for proper operation.

D. Factory test equipment and test methods shall conform to the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards, and shall be subject to the Owner/Engineer’s approval.

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PART 3 - EXECUTION


A. Installer shall be specialized in installing this type of equipment, with minimum 5 years documented experience. Experience documentation shall be submitted for approval prior to beginning work on this project.

3.2 EXAMINATION






3.3 INSTALLATION


B. Conduit hubs for use on raceway system pull and junction boxes shall be watertight, threaded aluminum, insulated throat, stainless steel grounding screw, as manufactured by T&B H150GRA Series, or equal.

C. Conduits entering a Control Panel, shall not enter the enclosure through the top.


3.4 RACEWAY SEALING

A. Where raceways enter junction boxes or control panels containing electrical or instrumentation equipment, entrances shall be sealed with 3M 1000NS Watertight Sealant, or approved equal.





C. Provide one set of as-built panel drawings laminated, in each panel pocket.

3.6 FIELD ADJUSTING



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3.7 FIELD TESTING


B. Megger and record phase to phase and phase to ground insulation resistance. Megger, for 1 minute, at minimum voltage of 1000 VDC. Measured Insulation resistance shall be at least 100 megohms. In no case shall the manufacturer’s maximum test voltages be exceeded.

C. Test each key interlock system for proper functioning.

D. Test all control logic before energizing the motor or equipment.

3.8 CLEANING






B. The Contractor shall provide three copies of the manufacturer's representative's certification.

3.11 TRAINING

A. Provide manufacturer's services for training of plant personnel in operation and maintenance of the soft start starters furnished under this Section.

B. The training for each type of equipment shall be for a period of not less than one eight hour day.





END OF SECTION

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Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16500 LIGHTING SYSTEM.DOCX

SECTION 16500 LIGHTING SYSTEM

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install a complete lighting system ready for operation as shown on the Drawings and as specified herein.

1.2 RELATED WORK


B. Section 16045 Electrical Support Hardware.

C. Section 16475

D. Low Voltage Enclosed Circuit Breakers and Disconnect Switches the Contract Documents shall be taken as a whole with every section related to every other section as required to meet the requirements specified. The organization of the Contract Documents into specification divisions and sections is for organization of the documents themselves and does not relate to the division of suppliers or labor which the Contractor may choose to employ in the execution of the Contract. Where references are made to other Sections and other Divisions of the Specifications, the Contractor shall provide such information or additional work as may be required in those references, and include such information or work as may be specified.

E. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submittals shall be made in accordance with the requirements of Division 1, Section 16000 and as specified herein. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

B. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will be returned without review.

C. Manufacturer's technical information for the materials proposed for use in the systems.

D. For all light pole foundations shown to be installed in earth, provide installation and anchoring drawings that are stamped and sealed by a licensed engineer in the state of [Texas] [Other]. The soil condition shall be assumed to be disturbed earth. If compaction is assumed, a compaction test shall be performed on all foundation locations, showing the minimum field density assumed in the foundation design.

E. Submit manufacturer's name and catalog data for all lighting equipment specified in this Section and on the lighting fixture schedule.

F. Shop drawings: Clearly indicate luminaire type, name of the job. Contractor shall endeavor to submit all luminaires, drivers and integral controls shop drawings at one time, in one package. Any re-submittals shall include all luminaire, driver and integral controls previously rejected or

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requiring further information. Specialty SSL, custom, or modified fixtures may be submitted as a separate package.

G. Shop Drawings: Reproductions of the Contract Drawings are not acceptable as shop drawings.

H. Product Data: Provide dimensions, ratings and specific catalog number and identification of items and accessories and performance data.

I. Shop Drawings: Indicate any dimensions and components for each luminaire that are not a standard product of the manufacturer.

J. Wiring Diagrams – as needed for special operation or interaction with other system(s).

K. Photometric Data: Where indicated below or for substitutions, supply complete photometric data for the fixture, including optical performance, rendered by NVLAP approved laboratory developed according to the methods of the Illuminating Engineering Society of North America. Submit electronically, in IESNA LM-63 standard format. Types XX and YY.

L. Submit photometric data for all substitute luminaries. Photometric reports are not required from specified manufacturer unless noted in paragraph H above.

M. Specification Sheets: If lacking sufficient detail to indicate compliance with Contract Documents, standard specification sheets will not be accepted. This includes, but is not limited to, luminaire type designation, manufacturer's complete catalog number, voltage, LED type, CCT, CRI, specific driver information, system efficacy, L70 life rating, and any modifications necessary to meet the requirements of the Contract Documents.

N. Substitutions shall include complete photometric data as outlined in paragraph H above, and point-by-point calculations for the specific conditions on the project. Samples shall be required for consideration of any substitutions and must be submitted in accordance with the terms outlined in paragraph below.

O. Working Samples of all substitutions: Samples shall be 120 Volt with cord and plug attached, and shall include specified LEDs and all modifications necessary to meet the requirements specified in the Contract Documents.

P. Energy Efficiency: 1. Submit documentation for Energy Star qualifications for equipment provided under work

of this Section. 2. Submit data indicating luminaire efficiency. 3. Submit data indicating Ballast Efficacy Factor (BEF). 4. Submit data indicating Luminaire Efficacy rating (LER). 5. Submit data indicating color rendition index of light source.

Q. Submit environmental data in accordance with Table 1 of ASTM E2129 for products provided under work of this Section.

R. Manufacturer's technical information for the materials proposed for use in the systems.

S. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. All lighting fixtures shall be in accordance with the National Fire Protection Association (NFPA) NFPA 70 “National Electrical Code” (NEC), and shall be constructed in accordance with the latest edition of the Underwriters Laboratories (UL) "Standards for Safety, Electric Lighting Fixtures".

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B. National Energy Policy Act of 2005, Public Law No. 109-58.

C. IESNA LM-63 - ANSI Approved Standard File Format for Electronic Transfer of Photometric Data and Related Information; 2002.

D. NFPA 70 - National Electrical Code; National Fire Protection Association; 2008.

E. IESNA LM-79-08 IESNA - Approved Method for Electrical and Photometric.

F. Measurements of Solid State Lighting Products; 2008.

G. IESNA LM-80-08 IESNA - Approved Method for Measuring Lumen Maintenance of LED Light Sources.

H. IESNA LM-80-08 IESNA - Approved Method for Measuring Lumen Maintenance of LED Light Sources.

I. IESNA TM-21-2011 – Projecting Long Term Lumen Maintenance of LED Light Sources.

J. UL 8750 – Light Emitting Diode (LED) Equipment for Use in Lighting Products.

K. OSHA 29CFR1910.7 – Luminaires shall be listed by national recognized testing laboratory approved by United Stated Department of Labor, Occupational Safety and Health Administration (OSHA).


A. All fixtures shall be of the energy-efficient type.

B. The manufacturer of these materials shall have produced similar lighting fixtures for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar systems shall be provided demonstrating compliance with this requirement.

C. The luminaires shall be manufactured in accordance with a manufacturer quality assurance (QA) program. The QA program shall include two types of quality assurance: (1) design quality assurance and (2) production quality assurance. The production quality assurance shall include statistically controlled routine tests to ensure minimum performance levels of the modules built to meet this specification. These tests shall include: CCT, CRI, Lumen output and wattage. Tests shall be recorded, analyzed and maintained for future reference.

D. QA process and test results documentation shall be kept on file for a minimum period of seven years.

E. LED luminaire designs not satisfying design qualification testing and the production quality assurance testing performance requirements described below shall not be labeled, advertised, or sold as conforming to this specification.

F. Equipment submitted shall fit within the space shown on the Drawings. Equipment which does not fit within the space is not acceptable.



B. Protect equipment during shipment, handling, and storage by suitable complete enclosures. Protect equipment from exposure to the elements and keep thoroughly dry.

C. Protect painted surfaces against impact, abrasion, discoloration, and other damage. Repaint damaged painted surfaces to the satisfaction of the Owner/Engineer.

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D. Equipment shall be installed in its permanent location shown on the Drawings within seven (7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7) calendar days, the equipment shall be stored on site in a dry heated and air conditioned space. If there is no such storage space on site, the equipment shall not be delivered to the site, but stored offsite, at the Contractor’s expense, until such time that the site is ready for permanent installation of the equipment.

1.7 WARRANTY

A. The Manufacturer shall warrant the system and equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty, the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Contractor at no expense to the Owner.

B. The manufacturer shall provide a warranty against loss of performance and defects in materials and workmanship for the Luminaires for a period of 5 years after acceptance of the Luminaires. Warranty shall cover all components comprising the luminaire. All warranty documentation shall be provided to customer prior to the first shipment.

C. The equipment shall be warranted to be free from defects in workmanship, design, and materials. If any part of the equipment should fail during the warranty period, it shall be replaced and the unit(s) restored to service at no additional cost (including parts, labor, and travel expenses) to the Owner.

D. The manufacturer’s warranty period shall run concurrently with the Contractor’s warranty period. No exception to this provision shall be allowed.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with the Contract Documents, the following Manufacturers are acceptable: 1. Lighting fixture manufacturers and types as required by the "Lighting Fixture Schedule"

on the Drawings. The catalog numbers are given as a guide to the design and quality of fixture desired.

2. Equivalent designs and equal quality fixtures of other manufacturers will be acceptable upon approval by the Owner/Engineer.


C. Where specified to match existing fixtures, fixtures of the same manufacturer and type shall be installed.

2.2 LIGHTING FIXTURES

A. General 1. All lamps shall be of one manufacturer and shall be as manufactured by Osram/Sylvania

Electric Products, Inc.; General Electric Co.; North American Philips Lighting Corp. or equal.

2. All ballasts shall be UL listed, ETL certified, Class "P", high power factor (minimum 0.90). 3. Ballasts shall have an "A" sound rating or better. 4. All ballasts used in exterior applications shall have a minimum starting temperature of 0

degrees F unless otherwise specified. 5. All interior ballasts shall have a minimum starting temperature of 50 degrees F.

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6. Ballasts shall be parallel wired type and designed to operate the number and length of lamps specified.

7. The total harmonic distortion (THD) of each ballast shall be 10% or less. 8. Ballasts shall have a minimum ballast factor of 0.88 = N and as specified in the fixture

schedule. 9. Ballasts shall have nominal power factor 0.90 or higher. 10. Ballasts shall have a maximum lamp current crest factor of 1.4. 11. Ballast shall provide normal rated life for the lamp specified. 12. All electronic ballasts shall be warranted for parts and replacement for 5 full years from

the date of installation. 13. All ballasts shall be as manufactured by G.E., Advance, Model Mark V, similar by

Osram/Sylvania; MagneTek or equal. 14. Where the equipment contains a programmable logic controller (PLC) or a uninterruptible

power supply (UPS), the equipment manufacturer shall furnish factory installed, a dedicated Point of Utilization Device (SPD), as specified in Section 16196, Individual Control Panel and Related Equipment Protection (Type 3).

B. LED Luminaires 1. Each luminaire shall consist of an assembly that utilizes LEDs as the light source. In

addition, a complete luminaire shall consist of a housing, LED array, and electronic driver (power supply) and integral controls as per this specification.

2. Each luminaire shall be designed to operate at an average operating temperature of 25°C.

3. The operating temperature range shall be 0°C to +25°C. Each luminaire shall meet all parameters of this specification throughout the minimum operational life when operated at the average operating temperature.

4. Nominal luminaire dimensions: refer to light fixture schedules.

C. Luminaire Construction: 1. Luminaire housing to have no visible welding, screws, springs, hooks, rivets, bare LEDs

or plastic supports. 2. The luminaire shall be a single, self-contained device, not requiring onsite assembly for

installation. The power supply and circuit board for the luminaire shall be integral to the unit.

3. Luminaires shall be fabricated from post painted cold rolled steel and shall be a rigid structure with integral T-bar clips.

4. Finish: Polyester powder coat painted with 92% high-reflective paint after fabrication. 5. Reflector: rugged one-piece cold rolled steel with embossed multi-facets, echoing the

frequency of the refractor prisms to distribute soft light at multiple angles, without flashing thus reducing high luminance contrast.

6. End caps shall be sloped at 70 degrees to create depth. 7. Luminaire to have smooth transition between T-bar and reflector arch. No doorframe or

exposed hardware. 8. Polymeric materials (if used) of enclosures containing either the power supply or

electronic components of the luminaire shall be made of UL94VO flame retardant materials. Luminaire lenses are excluded from this requirement.

9. Integral Grid Clips required on recessed mounted luminaires along with integral tie wire mounting points.

10. Luminaire to have air removal capability as specified. 11. The assembly and manufacturing process for the SSL luminaire shall be designed to

assure all internal components are adequately supported to withstand mechanical shock and vibration.

D. LED Sources 1. LEDs shall be manufactured by, Nichia, Samsung or Osram.26 51 13 Interior Lighting

Fixtures.

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2. Lumen Output – minimum initial lumen output of the luminaire shall be as follows for the lumens exiting the luminaire in the 0-90 degree zone - as measured by IESNA Standard LM-79-08 in an accredited lab. Exact tested lumen output shall be clearly noted on the shop drawings.

3. Lumen output shall not decrease by more than 20% over the minimum operational life of 50,000 hours.

4. Individual LEDs shall be connected such that a catastrophic loss or the failure of one LED will not result in the loss of the entire luminaire.

5. LED Boards shall be suitable for field maintenance or service from below the ceiling with plug-in connectors. LED boards shall be upgradable.

6. Light Color/Quality a. Correlated Color temperature (CCT) range as per specification, between 3500K,

4100K and 5000K shall be correlated to chromaticity as defined by the absolute (X,Y) coordinates on the 2-D CIE chromaticity chart.

b. The color rendition index (CRI) shall be 80 or greater. c. Color shift over 6,000 hours shall be <0.007 change in u’ v’ as demonstrated in

IES LM80 report.

E. Power Supply and Driver 1. Driver: AccuDrive, 120-277 Volt, UL Listed, CSA Certified, Sound Rated A+. Driver shall

be > 80% efficient at full load across all input voltages. Input wires shall be 18 AWG solid copper minimum.

2. Driver shall be suitable for full-range dimming. The luminaire shall be capable of continuous dimming without perceivable flicker over a range of 100% to 5% of rated lumen output with a smooth shutoff function. Dimming shall be controlled by a 0-10V signal.

3. Driver shall be UL listed. 4. Maximum stand-by power shall be 1 Watt. 5. Driver disconnect shall be provided where required to comply with codes. 6. The electronics/power supply enclosure shall be internal to the SSL luminaire and be

accessible per UL requirements. 7. The surge protection which resides within the driver shall protect the luminaire from

damage and failure for transient voltages and currents as defined in ANSI/IEEE C64.41 2002 for Location Category A, where failure does not mean a momentary loss of light during the transient event.

F. Electrical 1. Operation Voltage - The luminaire shall operate from a 50 or 60 HZ ±3 HZ AC line over

a voltage ranging from 120 VAC to 277 VAC. The fluctuations of line voltage shall have no visible effect on the luminous output. The standard operating voltages are 120 VAC, 277 VAC, 347 VAC.

2. Power Factor: The luminaire shall have a power factor of 90% or greater at all standard operating voltages and full luminaire output.

3. THD: Total harmonic distortion (current and voltage) induced into an AC power line by a luminaire shall not exceed 20 percent at any standard input voltage.

4. Surge Suppression: The luminaire shall include surge protection to withstand high repetition noise and other interference.

5. RF Interference: The luminaire and associated onboard circuitry must meet Class A emission limits referred in Federal Communications Commission (FCC) Title 47, Subpart B, Section 15 Non-Consumer requirements for EMI/RFI emissions.

6. Electrical connections between normal power and driver must be modular utilizing a snap fit connector. All electrical components must be easily accessible after installation and be replaceable without removing the fixture from the ceiling.

7. All electrical components shall be RoHS compliant.

G. Photometric Requirements 1. Luminaire performance shall be tested as described herein.

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2. Luminaire performance shall be judged against the specified minimum illuminance in the specified pattern for a particular application.

3. Luminaire lighting performance shall be adjusted (depreciated) for the minimum life expectancy (Section 2.2.5).

4. The performance shall be adjusted (depreciated) by using the LED manufacturer’s data or the data from the IESNA Standard TM-21 test report, which ever one results in a higher level of lumen depreciation.

5. The luminaire may be determined to be compliant photometrically, if: a. The initial minimum illuminance level is achieved in 100% of the area of the

specified lighting pattern. b. The measurements shall be calibrated to standard photopic calibrations. c. Add specific project requirements.

H. Thermal Management 1. The thermal management (of the heat generated by the LEDs) shall be of sufficient

capacity to assure proper operation of the luminaire over the expected useful life (Section 1.2.9 c).

2. The LED manufacturer’s maximum junction temperature for the expected life (Section 1.2.9 c) shall not be exceeded at the average operating ambient (Section 1.2.4).

3. The LED manufacturer’s maximum junction temperature for the catastrophic failure shall not be exceeded at the maximum operating ambient (Section 1.2.5).

4. The luminaire shall have an UL IC rating. 5. The Driver manufacturer’s maximum case temperature shall not be exceeded at the

maximum operating ambient. Thermal management shall be passive by design. The use of fans or other mechanical devices shall not be allowed.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The location of lighting fixtures shown on the Drawings is approximate. The Contractor shall install the lighting fixtures after major ducts and piping are installed, to avoid conflicts. He shall install the fixtures to avoid shadows and blocking of light, relocating the fixtures as necessary, at no cost to the Owner.

B. Each fixture shall be a completely finished unit with all components, mounting and/or hanging devices necessary, for the proper installation of the particular fixture in its designated location and shall be completely wired ready for connection to the branch circuit wires at the outlet.

C. All flush mounted fixtures shall be supported fro3m the structure and shall not be dependent on the hung ceilings for their support.

D. Fixtures noted to be installed flush in suspended ceilings shall be of mounting types suited for the type ceiling involved. Troffers (2 X 4), provided in suspended ceiling grids, shall be installed with safety clips to hold the fixture securely in the ceiling grid. It shall be the responsibility of the Contractor to verify the ceiling types prior to ordering fixtures.

E. Flexible fixture hangers shall be used for all pendant mounted fixtures. Fixtures 2-ft long and larger shall be supported with a minimum of two fixture hangers.

F. Conduit run in areas with hung ceilings shall be installed in the space above the hung ceiling as close to the structure as possible. Conduits shall be supported from the structure.

G. Exterior lighting poles shall be mounted plumb.

H. Fixture locations are shown on the Drawings in approximate locations; however, exact locations shall be coordinated so as to avoid conflicts with HVAC ducts, equipment and other obstacles.

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3.2 REPLACEMENT

A. Lamps (except for H.I.D.) used during the building construction, prior to 2 weeks from completion of the work, shall be removed and replaced with new lamps.

3.3 CLEANING UP

A. Clean electrical parts to remove conductive and deleterious materials.

B. Remove dirt and debris from lens enclosures. 1. For cleaning acrylic lenses or diffusers, use a feather duster or dry cotton cheesecloth to

rid the lens/diffuser of any minor dust. For fingerprints, smudges, or other dirt present, use an ammonia-based cleaner (such as Windex) and wipe carefully with cotton cheesecloth (so as to avoid injury from any prismatic texture of the lens).

2. Job site contamination may not necessarily be removed using the above recommendations. In that case the lens would need to be replaced.

C. Clean photometric control surfaces as recommended by manufacturer.

D. Plastic dust cover bags to be provided with new parabolic reflector lighting fixtures shall be removed after all construction activity that may cause dust formation on reflector surfaces has been completed.

E. All fixtures shall be left in a clean condition, free of dirt and defects, before acceptance by the Owner/Engineer.

END OF SECTION

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UNDERGROUND SYSTEM Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16600 UNDERGROUND SYSTEM.DOCX

SECTION 16600 UNDERGROUND SYSTEM

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish and install a complete underground system of raceways, manholes and handholes as shown on the Drawings and as specified herein.

B. Raceways for use in structural concrete is specified in Section 16110 Raceways, Boxes and Fittings.

1.2 RELATED WORK


B. Section 16033 Cast-in-Place Concrete for Electrical Applications.


D. Section 16110 Raceways, Boxes and Fittings

E. Section 16120 Wire and Cables (600 Volt Maximum).

1.3 SUBMITTALS

A. Submit to the Engineer, in accordance with Division 1 and Section 16000, shop drawings and product data, for the following: 1. Manholes, handholes and associated hardware. 2. Plastic duct spacers

B. Submittals shall also contain information on related equipment to be furnished under this Specification but described in the related Sections listed in the Related Work paragraph above. Incomplete submittals not containing the required information on the related equipment will be returned unreviewed.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NFPA 70 – National Electrical Code (NEC) 2. NFPA 70E – Standard For Electrical Safety in the Workplace 3. ASTM A615/A615M-06a – Standard Specification for Deformed and Plain Carbon-Steel

Bars for concrete Reinforcement 4. ASTM A48 – Standard Specification for Gray Iron Castings 5. ASTM A536 - Standard Specification for Ductile Iron Castings 6. AASHTO M306-04/ ASTM A48 – Drainage Structure Castings, Section 7.0 Proof Load

Testing 7. ASTM C-850- Specifications for underground precast concrete utility structures

B. All excavation, trenching, and related sheeting, bracing, etc., as shown on the Drawings and listed in these Specifications, shall comply with the following standards (unless otherwise noted): 1. Occupational Safety and Health Administration (OSHA)

a. Excavation safety standards (29 CFR Part 1926.650 Subpart P) - Excavation. 2. American Society for Testing and Materials (ASTM)

a. ASTM D 698a – Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600kN-m/m3)).

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C. All equipment components and completed assemblies specified in this Section of the Specifications shall bear the appropriate label of Underwriters Laboratories.



B. The precast manholes shall be manufactured in a NPCA (National Precast Concrete Association) Certified Plant.




C. Materials shall not be stored exposed to sunlight. Such materials shall be completely covered.

D. Materials showing signs of previous or jobsite exposure will be rejected.

1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment, or materials shall be performed by the Contractor at no expense to the Owner.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Raceway System 1. Raceway system shall be Schedule 40 PVC Rigid Nonmetallic Conduit (RNC), designed

for use aboveground and underground as described in the NEC, resistant to sunlight. The conduits and fittings shall be manufactured to NEMA TC-2, Federal Specification WC1094A and UL 651 specifications. Minimum raceway size shall be 2 inch. Fittings shall be manufactured to NEMA TC-3, Federal Specification WC1094A and UL 514B. Conduit shall have a UL Label. Conduit shall be Carlon, Kraloy, or approved equal.

2. PVC coated rigid aluminum conduit shall have a minimum 0.040-in thick, polyvinyl chloride coating permanently bonded to rigid aluminum conduit and an internal chemically cured urethane or enamel coating. Rigid aluminum conduit shall be as manufactured by the Allied Tube and Conduit Corp.; Wheatland Tube Co.; Triangle PWC Inc. or equal. The ends of all couplings, fittings, etc. shall have a minimum of one pipe diameter in length of PVC overlap. PVC coated conduit and fittings shall be as manufactured by Perma-Cote, Robroy Industries, Triangle PWC Inc. or Ocal. Any field bends shall be made using equipment designed to prevent damage to the PVC coating.

3. All underground raceways of the underground system, terminating in manholes or handholes shall use terminators of the same size and type as the raceway

4. Blank Duct Plugs shall be sized for the duct installed on, and shall be TYCO Type JM-BLA-XXDXXXCR, with rubber gasket, or approved equal.

5. Duct spacers shall be as manufactured by Carlon or equal.

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6. Where raceways terminate into existing and new manholes, handholes or structures, the duct bank steel shall be anchored into the manhole, handhole or structure with a Hilti HIT 150 MAX epoxy anchoring system. The termination of the duct bank steel shall utilize a minimum 24-inch length of reinforcing bar anchored not less than 4 inches into the manhole, handhole or structure wall, and lapped into each reinforcing bar in the duct bank.

7. Concrete encasement for raceways and duct banks shall be normal weight concrete weighing not more than 145 pcf with compressive strength, a minimum of 3000 psi, or greater if required by other Divisions of the Specifications, at 28 days, Concrete shall have crushed aggregate with a maximum size of ¾-inch, a slump of 4 – 6 In. and flow freely without the use of vibrators. Install red dye of 40 lbs per 10 cy. of concrete, installed in the truck at the concrete plant.

8. Reinforcing steel shall comply with ASTM A615 Grade 60 and of a size and installation as shown on the Drawings.

PART 3 - EXECUTION

3.1 GENERAL

A. The Contractor shall field verify the routing of all underground duct banks before placement. He shall modify the routing as necessary to avoid underground utilities or above ground objects. Modification or rerouting for the convenience of the Contractor, or to reduce the length of duct run as designed, will not be permitted. The Contractor shall provide any alternate routing of the duct banks to the Owner/Engineer and, after approval, shall proceed with the installation.

B. All changes of direction, less than 20 degrees, shall be made using a hotbox, strictly in conformance with the conduit manufacturer’s instructions. Changes of direction greater than 20 degrees shall be accomplished using long radius bends of PVC coated rigid aluminum conduit.

C. The Contractor shall saw cut and repair existing pavements above new and modified existing duct banks. The Contractor shall provide the alternate routing of the duct banks to the Owner/Engineer and after approval shall proceed with the installation.

D. Install raceways to drain away from buildings. Raceways between manholes or handholes shall drain toward the manholes or handholes. Raceway slopes shall not be less than 3 in per 100 ft.

E. Reinforce raceway banks as shown on the Drawings.

F. A #4/0 stranded bare tinned copper ground conductor shall be installed along the top of the rebar cage, as shown on the Drawings, for the full length of each duct run between manholes and handholes, and bonded to a ground rod in the vicinity of each manhole and handhole.

G. Lay raceway lines in trenches on compacted earth as specified herein.

H. Use plastic spacers located not more than 4 ft apart to hold raceways in place. Spacers shall provide not less than 2-inch clearance between raceways.

I. The minimum cover for raceway banks shall be 24 in unless otherwise permitted by the Owner/Engineer.

J. Raceway terminations at all manholes, existing and new, shall be with terminator for PVC conduit.

K. Blank duct plugs shall be used to seal the ends of all unused ducts in the duct system. Plugs shall be installed at all locations where the ducts enter and leave the manholes or handholes, and all entrances and exits to the underground system.

L. Where raceways enter or exit the Underground System, and the raceways rise to a higher elevation upon entering or leaving the System, such raceways shall be tightly sealed at the

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higher elevation, both before and after the installation of cables, such that there shall be no entry of water or moisture to the Underground System at any time. Raceways shall be sealed with 3M 1000NS Watertight Sealant, or approved equal.

M. No wire shall be pulled until the duct system has been completed in every detail.

N. Swab all raceways clean before installing cable.

O. Train cables in manholes and handholes and support and restrain them on cable racks. All cables passing manhole duct entrances in the manhole or handhole shall pass above all duct entrances. No cable shall pass in front of or below duct bank entrances.

P. Polyethylene Warning Tape shall be installed in the trench above each raceway or duct bank and located at the elevations shown on the Drawings.

Q. The Contractor shall tag all underground conduits at all locations, exiting and entering from underground, including manholes and handholes.

3.2 TRENCH EXCAVATION

A. The excavation shall extend to the width and depth as shown on the Drawings, or as specified, and shall provide suitable room for installing manholes, handholes, ducts and appurtenances.

B. Furnish and place all sheeting, bracing and supports.

C. Excavation shall include material of every description and of whatever substance encountered, regardless of the methods or equipment required to remove the material. Pavement shall be cut with a saw, wheel or pneumatic chisel along straight lines before excavating.

D. The Contractor shall strip and stockpile topsoil from grassed areas crossed by trenches. At the Contractor’s option, topsoil may be otherwise disposed of and replaced, when required, with approved topsoil of equal quality.

E. While excavating and backfilling is in progress, traffic shall be maintained, and all utilities and other property protected, as provided for in the Contract Documents.

F. Materials shall be excavated to the depth indicated on the Drawings and in widths sufficient for installing manholes and laying the ducts. Coordinate the trench width the Details shown on the Drawings. The bottom of the excavations shall be firm and dry in all respects acceptable to the Owner/Engineer. Trench width shall be a practical minimum, but not less than 6 inches greater on each side, than the total duct section arrangement, including reinforcing steel.

G. Excavation and dewatering shall be accomplished by methods which preserve the undisturbed state of sub grade soils. The trench may be excavated by machinery to, or just below, the designated sub grade, provided that material remaining in the bottom of the trench is no more than slightly disturbed. Sub grade soils which become soft, loose or otherwise unsatisfactory as a result of inadequate excavation, dewatering or other construction methods, shall be removed and replaced by gravel fill, of aggregate as specified herein, as required by the Owner/Engineer at the Contractor’s expense.

3.3 EXCAVATION BELOW GRADE AND REFILL

A. Regardless of the nature of unstable material encountered, or the groundwater conditions, trench and excavation drainage shall be complete and effective.

B. If deemed necessary by the Owner/Engineer, or as shown on the Drawings, the Contractor shall be required to deposit pea gravel for duct bedding or gravel refill for excavation below grade, directly on the bottom of the trench immediately after excavation has reached the proper depth and before the bottom of the trench has become softened or disturbed by any cause whatsoever. All excavation shall be made in open trenches. Gravel used for this purpose, shall be aggregate, as specified that is ≤ 1/2 the minimum clear spacing between electrical ducts, and a maximum coarse aggregate size of ¾-inch.

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3.4 BACKFILLING

A. Remove from the excavation all materials which the Owner/Engineer may deem unsuitable for backfilling.

B. Backfilling shall not commence until, not less than 48 hrs after placing of any concrete embedment, have lapsed.

C. Where the duct banks are laid in the yard, the remainder of the trench, after concrete encasement, shall be filled with common fill material, void of rock or other non-porous material, in layers not to exceed 8-in in loose measure and compacted to 90% standard Proctor density at optimum moisture content of +/- 4%. The backfill shall be mounded 6-in above the existing grade or as directed by the Owner/Engineer. Where a grass, loam or gravel surface exists prior to excavations in the yard, it shall be removed, conserved and replaced to the full original depth as part of the work under the duct items. In some areas it may be necessary to remove excess material during the cleanup process, so that the ground may be restored to its original level and condition.

D. Where the duct banks are laid in paved areas or designated future paved areas, existing or designated future structures, or other existing or future utilities, the remainder of the trench above the encasement, shall be backfilled with select common fill or select fill material in layers not to exceed 8-inches loose measure and compacted at optimum moisture content (+/- 3%) to 95 percent standard Proctor density.

E. Compaction shall be by use of hand or pneumatic tamping with tools weighing at least 20 lbs. The material being spread and compacted shall be placed in layers not over 8-in loose thick. If necessary, sprinkling shall be employed in conjunction with rolling or ramming.

F. Bituminous paving shall not be placed in backfill.

G. Water jetting will not be accepted as a means of consolidating or compacting backfill.

H. All road surfaces shall be broomed and hose-cleaned immediately after backfilling. Dust control measures shall be employed at all times.

3.5 RESTORING TRENCH AND ADJACENT SURFACES

A. In paved areas, the edge of the existing pavement to be removed shall be cut along straight lines, and the pavement replaced with the same type and quality of the existing paving.

B. In sections where the duct bank passes through grassed areas, the Contractor shall, at his own expense, remove and replace the sod, or shall loam and reseed the surface to the satisfaction of the Owner/Engineer.

3.6 CLEANING

A. Remove all rubbish and debris from inside and around the underground system. Remove dirt, dust, or concrete spatter from the interior and exterior of manholes, handholes and structures, using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.

END OF SECTION

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GROUNDING AND BONDING SYSTEM Z:\667_FLOWER MOUND WWTP REHAB PHASE IV SOLIDS FACILITY IMPROVEMENTS PART 1\6 SPECIFICATIONS\ELECTRICAL\!WORKING\16660 GROUNDING AND BONDING SYSTEM.DOCX

SECTION 16660 GROUNDING AND BONDING SYSTEM

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required to install a complete Grounding and Bonding System, in strict accordance with Article 250 of the National Electrical Code (NEC), and as shown on the Drawings and specified herein.

B. The system shall include ground wires, ground rods, exothermic connections, mechanical connectors, structural steel connections, all as shown on the Drawings, and as specified herein, to provide a bonding to earth ground of all metallic materials likely to become energized.

C. The Bid Price shall be in complete compliance with the Contact Documents. Any exception shall be included in the bid with a detailed explanation that clearly indicates the paragraph of this Specification and / or the item in the Drawings to which the exception applies. The Contractor shall explain in detail the reasons for the exception. The inclusion of an exception and its explanation as specified shall not constitute any obligation on the part of the Engineer / Owner to accept the Bid Price with the exception.

D. This Specification shall have precedence over any conflict in the bidders submittals and / or descriptive information and the Contract Documents unless an exception is made at the time of bidding as specified herein, and the bid price is accepted with the bidder’s exception by the Engineer / Owner.

E. The Contractor shall provide all tools, equipment, supplies, and shall perform all labor required to install the equipment specified in the Contract Documents in order to install, test, and place into satisfactory operation in the time specified for completion in the Contract Documents. Failure of any of the Contractors sub-contractors or suppliers to perform the work as specified shall not constitute an acceptable reason for the Owner to grant any change in the Contract Price or additions to the Contract Time.

1.2 RELATED WORK


B. Section 16110 Raceways, Boxes and Fittings.


D. Section 16120 Wire and Cables (600 Volt Maximum).






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J. The Contractor shall be responsible for examining all Sections of the Specifications and Drawings, and shall determine the power and wiring requirements and shall provide external wiring and raceways, as required to provide a fully functioning power, control and process control systems. If the equipment requires more conductors and/or wiring, due to different equipment being supplied, the Contractor shall furnish the additional conductors, raceways and/or wiring, with no change in the Contract Price, and with no increase in Contract Time.

1.3 SUBMITTALS

A. Submit to the Engineer, in accordance with Division 1and Section 16000, shop drawings and product data, for the following: 1. Ground rods. 2. Grounding conduit hubs. 3. Water pipe ground clamps. 4. Buried grounding connections. 5. Compression lugs. 6. Exothermic bonding system.

B. All cut sheets shall be clearly marked to indicate which products are being submitted for use on this project. Unmarked cut sheets will be cause to reject the submittal and return it for revision.

C. All shop drawing submittals and all O&M submittals shall be submitted in hard copy format and in electronic format using PDF files including a Table of Contents which is indexed on DVDs. Electronic submittals are mandatory and those which are received not indexed as specified will be returned without review. Hard copy submittals may not be required if so stipulated in the Contract Documents. No change in Contract Amount or Contract Time will be allowed for delays due to unacceptable submittals.


A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NFPA 70 – National Electrical Code (NEC) 2. UL 467-2007 --Grounding and Bonding Equipment 3. NFPA 70E – Standard for Electrical Safety in the Workplace






B. Protect equipment during shipment, handling, and storage by suitable complete enclosures. Protect equipment from exposure to the elements and keep thoroughly dry.

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1.7 WARRANTY

A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for 1 year from date of final acceptance of the equipment. Within such period of warranty, the Manufacturer shall promptly furnish all material and labor necessary to return the equipment to new operating condition. Any warranty work requiring shipping or transporting of the equipment, or materials, shall be performed by the Contractor at no expense to the Owner.

PART 2 - PRODUCTS

2.1 RACEWAYS

A. Conduit shall be as specified under Section 16110.

B. All raceways, conduits and ducts shall contain equipment grounding conductors sized in accordance with the NEC. Minimum sizes shall be No. 12 AWG unless otherwise indicated on the drawings.

2.2 CONDUCTORS

A. Wire shall be as specified under Section 16120.

B. Equipment grounding conductors shall be tinned insulated XHHW-2 conductors. Conductors shall be green where available from the wire manufacturers, or marked with green tape as specified under 16120.

C. Grounding electrode conductors shall be bare tinned copper where direct buried, or encased in concrete. Bare grounding electrode conductors or lightning protection conductors where exposed to damage shall be installed in conduit. Grounding electrode conductors or lightning protection down lead conductors shown, specified or required to be installed in conduit per the NEC with no other conductors shall be bare tinned copper. Bare conductors installed in metallic conductors shall be bonded to the metallic conduit at both ends.

D. Grounding electrode conductors routed between concealed grounding electrodes or interconnecting grounding electrode counterpoise loop conductors to exposed (IE “Pigtails”) shall be bare tinned copper.

2.3 GROUNDING ELECTRODES

A. Ground rods shall be 3/4 in by 10 ft. copper clad steel and constructed in accordance with UL 467. The minimum copper thickness shall be 10 mils. Ground rods shall be as manufactured by ERICO, Copperweld or Hager.

2.4 CONNECTORS AND CONNECTIONS

A. Waterpipe ground clamps shall be 316 stainless steel, Thomas & Betts Co. Cat. JPT, similar by Burndy; O.Z. Gedney Co. Cooper Power Systems, Erico, or Harger. The Contractor shall determine and provide the correct size for the pipe.

B. Other grounding system clamps, where specified or shown shall be 316 stainless steel as provided by Thomas & Betts Co. Burndy; O.Z. Gedney Co. Cooper Power Systems, Erico or Harger.

C. All concealed grounding system or lightning protection system connections shall be by an exothermic weld process, T&B Furseweld SCR1, Burndy Thermoweld, Cadweld, or equal. Exothermic welded connections shall be used in exposed locations as specified herein.

D. Concealed grounding connections which require exothermic welding which are in a Class 1 Division 1 Area as determined by NFPA 820, or the Engineer, or the NEC Authority Having Jurisdiction shall use a Burndy Hyground Irreversible Compression System, or equal.

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PART 3 - EXECUTION

3.1 INSTALLATION

A. Route exposed grounding electrode conductors in rigid aluminum conduits to protect the conductors from damage. The rigid conduits shall be aluminum or PVC-coated aluminum conduits as specified in 16110. Bond the protecting conduits to the grounding electrode conductors at both ends. Do not allow water pipe connections to be painted. If the connections are painted, disassemble them and remake them with new fittings.

B. Install equipment grounding conductors in all raceways for the power, control and instrumentation systems. Grounding conductors shall be independent conductors and shall be separate from all shield drain wires.

C. Conduits and other raceways shall contain an equipment grounding conductor whether the raceway is metallic or not. Conduits, motors, cabinets, outlets and other equipment shall be properly bonded in accordance with NEC requirements. Where ground wire is exposed to mechanical damage, install wire in rigid metallic conduit.

D. Bond all steel building columns in new structures together with ground wire in rigid conduit and connect to the distribution equipment ground bus. Ground wire connections to structural steel columns shall be made with exothermic welds. In existing structures where grounding electrodes are being added, bond all steel building columns together with grounding electrode conductors in rigid metallic conduit and connect to the distribution equipment ground bus, whether or not shown on the Drawings.

E. In NEC classified areas, connection of grounding electrode connections to structural steel columns shall be made with long barrel type one-hole heavy duty copper compression lugs, bolted through 1/2 in maximum diameter holes drilled in the column web, with stainless steel hex head cap screws and nuts.

F. In new construction, bond each building column to the grounding electrode counterpoise system whether nor not specifically shown on the Drawings. The grounding electrode conductor between the concealed counterpoise grounding counterpoise electrodes and the building steel shall be an insulated conductor. The insulated grounding insulated conductor shall be shall be bonded to the building column using an exothermic type weld as specified herein.

G. Metal conduits stubbed into a motor control center shall be terminated with insulated grounding bushings and connected to the motor control center ground bus. Bond boxes mounted below motor control centers to the motor control center ground bus. Size the grounding wire in accordance with NEC Table 250.122, except that a minimum No. 12 AWG shall be used.

H. Liquid tight flexible metal conduit in sizes 1-1/2 in and larger shall have bonding jumpers. Bonding jumpers shall be external, run parallel (not spiraled) and fastened with plastic tie wraps.

I. Ground transformer neutrals to the nearest available grounding electrode with a conductor sized in accordance with NEC Article 250.66.

J. Provide power system grounding electrodes (ground rods) no closer than twice the length of the ground rod. Where a lightning protection is specified to be provided, the Contractor shall provide a dedicated lightning protection system grounding electrodes (ground rod) at the end of every down lead without regard to the location of the power system grounding electrodes. Bond each lighting protection system grounding electrode to the power system counterpoise system. Refer to Section 16670 for lightning protection system specifications.

K. Provide a 1/0 AWG bare tinned grounding conductor the full length of each cable tray system, bond each section and tray fitting to the tray grounding conductor. Route the tray grounding conductor along the outside of the cable tray. Install no grounding clamps on the inside of the tray to avoid damage to tray conductors. Bond the tray grounding conductor to the power

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system counterpoise grounding electrode system at the end of the tray, or for tray systems installed in a loop configuration, bond in at least two locations at opposite sides of the tray loop. Bond every enclosure to which tray conductors are routed to the tray grounding conductor. Bond every conduit or raceway routing tray conductors away from or to the tray system to the cable tray and to the cable tray grounding conductor.

L. All equipment enclosures, motor and transformer frames, conduits systems, cable tray, cable armor, exposed structural steel and all other equipment and materials required by the NEC to be grounded, shall be grounded and bonded in accordance with the NEC.

M. Seal exposed connections between different metals with no-oxide paint, Grade A or equal.

N. Lay all underground grounding conductors slack and, where exposed to mechanical injury, protect by pipes or other substantial guards. If guards are iron pipe, or other magnetic material, electrically connect conductors to both ends of the guard. Make connections as specified herein.

O. Care shall be taken to ensure good ground continuity, in particular between the conduit system and equipment frames and enclosures. Where necessary, bonding jumper conductors shall be provided.

P. All grounding type receptacles shall be grounded to the outlet boxes with a minimum, #12 XHHW-2 stranded green conductor, connected to the ground terminal of the receptacle and bonded to the outlet box by means of a grounding screw.

3.2 INSPECTION AND TESTING

A. Inspect the grounding and bonding system conductors and connections for tightness and proper installation.

B. Use Biddle Direct Reading Earth Resistance Tester or equivalent test instrument to measure resistance to ground of the system. Perform testing in accordance with test instrument manufacturer's recommendations using the fall-of-potential method.

C. All test equipment shall be provided under this Section and approved by the Owner/Engineer.

D. Resistance to ground testing shall be preceeded by no precipitation for a minimum of 5 days. Submit test results in the form of a graph showing the number of points measured (12 minimum) and the numerical resistance to ground.

E. Testing shall be performed before energizing the electrical distribution system.

F. A separate test shall be conducted for each building or system.

G. Notify the Engineer immediately if the resistance to ground for any building or system is greater than five ohms.

END OF SECTION