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Received SVBX PDCC October 22, 2012

4_DU-013 RFC Combined Specs-Track Changes.pdf

P0728-C700-DU-013.RFC.R0

SSH JV

SCVWD 66" Central Pipeline (DU013) Technical Specifications Ready for Construction

SVBX C700

Friday, October 19, 2012

A I t O A DAtY COMPANY

T Y L I N INTERNATIONAL •engineers I plohtie's | scientists

B1210-F350

4 _ D U - 0 1 3 R F C C o m b i n e d S p e c s - T r a c k C h a n g e s . p d f

SCVWD 66" CENTRAL PIPELINE (DU013)

TECHNICAL SPECIFICATIONS TABLE OF CONTENTS

DIVISION 33 UTILITIES

33 05 16 Utility Structures 33 05 25 Support and Protection of Utilities 33 05 28 Trenching and Backfilling for Utilities 33 11 02 SCVWD Water Pipelines 33 11 03 Hydrostatic Testing, Disinfection and Bacteriologic Testing Procedure

Santa Clara Valley Transportation Authority NO EXCEPTION TAKEN MAKE CORRECTIONS NOTED

>< AMEND AND RESUBMIT Any action shown above is subject to the terms of the contract and does not relieve the contractor

of any of its obligations under the contract including design and detailing.

Resubmit Specs to include all referenced Specification Sections relevant to the Work in this Design Unit Work Package. Incorporate comments from the RFC review. Specs must be signed and sealed by a licensed CA PE.

1B11002F Contract

roukis_r

Text Box

P0728-C700-DU-013.R0 B1210 F350

TECHNICAL SPECIFICATIONS

SECTION 33 11 02

SCVWD WATER PIPELINES

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Buried pipe and fitting

B. Valves

C. Thrust blocks and harnessing

D. Field quality control

E. Test

F. Connections to existing mains

1.02 RELATED SECTIONS

A. Concrete is specified in Section 03 05 15, Portland Cement Concrete.

B. Section 27 15 01, Telemetry

C. Section 33 05 16, Utility Structures

D. Section 33 05 28, Trenching and Backfilling for Utilities

E. Section 33 11 03, Hydrostatic Testing, Disinfection and Bacteriologic Testing Procedure

1.03 MEASUREMENT AND PAYMENT

Separate measurement or payment will not be made for Work required under this Technical Specifications Section. All costs in connection with the Work specified in this Technical Specifications Section will be considered to be included with the related item of Work in the Price Schedule or incidental to the Work.

1.04 REFERENCES

A. American Society for Testing and Materials (ASTM):

1. ASTMA126 Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

2. ASTM A307 Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile

3. ANSI/ASTM A234 Specification for Piping Fittings of Wrought Carbon Steel and

October 19, 2012 33 11 02 - 1 Contract C700; DU-012, WP01 & DU-013 SCVWD Water Pipelines Ready for Construction


Alloy Steel for Moderate and High Temperature Service

4. ANSI/ASTM A283 Specification for Low and Intermediate Tensile Strength Carbon Steel Plates

5. ANSI/ASTM F436 Specification for Hardened Steel Washers

6. ANSI/ ASTM D638 Standard Test Method for Tensile Properties of Plastics

7. ANSI/ASTM D1000 Standard Test Methods for Pressure-Sensitive Adhesive-Coated Tapes Used for Electrical and Electronic Applications

8. ASTM A194 Specification for Carbon Steel Nuts

9. ASTM A193 Specification for Carbon Steel Bolts and Studs, 125 ksi Tensile

B. American Water Works Association (A WW A):

1. AWWA C200 Steel Water Pipe~6 In. (150 mm) and Larger

2. AWWA C203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines-Enamel and Tape-Hot-Applied

3. AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe—4 In. (100 mm) and Larger—Shop Applied

4. AWWA C206 Field Welding of Steel Water Pipe

5. AWWA C207 Steel Pipe Flanges for Waterworks Service—Sizes 4 In. Through 144 In.

6. AWWA C208 Dimensions for Fabricated Steel Water Pipe Fittings

7. AWWA C210 Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines

8. AWWA C213 Fusion-Bonded Epoxy Coatings for the Interior and Exterior of Steel Water Pipelines

9. AWWA C214 Tape Coating Systems for the Exterior of Steel Water Pipelines

10. AWWA C216 Heat Shrinkable Cross-Linked Polyolefin Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines

11. AWWA C217 Petrolatum and Petroleum Wax Tape Coatings for the Exterior of Connections and Fittings for Steel Water Pipelines

12. AWWA C222 Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings

Contract C700; DU-012, WP01 & DU-013 33 11 02 - 2 October 19,2012 Ready for Construction SCVWD Water Pipelines


13. AWWA C504 Rubber-Seated Butterfly Valves

14. AWWA C550 Protective Interior Coatings for Valves and Hydrants

15. AWWA Ml 1 Steel Water Pipe: A Guide for Design and Installation

C. Water District Requirements: Note that all work shall be performed and completed in accordance with the Santa Clara Valley Water District requirements. The Contractor shall be responsible for obtaining all such requirements and for compliance with such requirements as applicable.

D. Caltrans Standard Specifications Section 75-1.03, "Miscellaneous Bridge Metal"

E. American Railway Engineering and Maintenance-of-Way Association: Manual for Railway Engineering, 2007

1.05 SUBMITTALS

A. Refer to Section 01 33 00, Submittal Procedures, and Section 01 33 23, Shop Drawings, Product Data, and Samples, for submittal requirements and procedures.

B. Submit respective manufacturer's product data for manufactured materials and equipment, including all valves and appurtenances.

C. Submit Shop Drawings showing piping laying and pipe, including lay sheets, valves, hydrants, and locations of tie-ins, buttresses, and thrust blocks.

D. Submit welder's certificates for the welders performing the work. (AWS Certificates)

1.06 SUBMITTALS FOR CLOSEOUT

A. General: Refer to Section 01 77 00, Closeout Procedures, and Section 01 78 23, Operation and Maintenance Data, for submittal requirements and procedures.

B. Record Drawings: Record actual location of piping mains, valves, connections, and invert elevations for review.

1.07 SITE CONDITIONS

A. Excavations in which products will be buried shall be dry.

B. Coordinate the installation of the water supply system with the jurisdictional water utility owner.

C. The jurisdictional water utility district shall provide water services to the water meters' points of connection for station facilities and landscape irrigation systems, and modifications to existing water mains, as indicated on the Drawings. The Contractor shall be responsible for making all such arrangements.

October 19, 2012 SCVWD Water Pipelines

33 11 02 - 3 Contract C700; DU-012, WP01 & DU-013 Ready for Construction


PART 2 - PRODUCTS

2.01 BURIED PIPE AND FITTINGS

A. General: This pressure pipe is intended for the transmission of either untreated drinking water source (66" Central Pipeline) or drinking water source (42" Milpitas Pipeline). All materials which may be in contact with the transportation of either untreated drinking water or drinking water shall be in conformance with applicable AWWA standards and NSF Certifications.

B. Steel Pipe and Fittings: Fabricate and supply miscellaneous steel pipe and fittings in accordance with AWWA C200, C207, C208 and AWWA M i l except as modified herein. Steel to be minimum of ASTM A 36, ASTM A 53 Grade B, ASTM A 135 Grade B, ASTM A 139 Grade B, ASTM A 1011 Grade 36, or ASTM A 1018 Grade 36.

C. Steel Pipe Design Conditions:

1. Design pipe and fittings to withstand most critical simultaneous application of external loads and internal pressures. Base design on minimum of AASHTO HS-20 loading, AREMA E-80 loads and depths of bury as indicated on Drawings. Design pipes with Marston's earth loads for transition width trench for all heights of cover.

2. Groundwater Level: Design for most critical groundwater condition.

3. Design Pressure: 475 feet of head for 66-inch diameter, 615 feet of head for 42-inch diameter.

4. Hydrostatic field test pressure: 110% of the design pressure

5. Maximum deflection from specified diameter: 2% for cement mortar coated pipe and 3% for pipe with flexible coating.

6. Stress due to design pressure to be no greater than 50 percent of minimum yield, and stress not to exceed 16,500 psi for mortar coated pipe, or 21,000 psi for flexible coated steel.

7. Modulus of soil reaction (E') shall be between 700 and 1500 psi depending upon compaction and fill heights in accordance with Table 6-1 of AWWA M i l . Unit weight of fill (w) >130 pcf.

8. Deflection lag factor (Dl) = 1.2.

9. Bedding constant (K) = 0.1.

10. Fully saturated soil conditions: hw = h = depth of cover above top of pipe.

11. Do not allow diameter (D) over thickness (t) ratio to be greater than 230.

D. Steel Pipe Joints: Except where specifically required otherwise all steel pipe shall be either Contract C700; DU-012, WP01 & DU-013 33 11 02 - 4 October 19,2012 Ready for Construction SCVWD Water Pipelines


single-welded lap or butt-strap welded joints as shown on the Drawings. Field welding of

joints shall conform to AWWA C206.

1. Provide full circumferential joint welds.

2. Use wire and flux from same manufacturer throughout project. 3. In areas of welded joints, one joint in each 400 feet of continuous welded joints (plus

or minus 40 feet) shall be left unwelded until the time of maximum thermal contraction (as determined by the VTA), at which time the joint shall be welded.

4. Unless otherwise indicated, pipe flanges shall be Class F conforming to the requirements of AWWA C207 for steel ring type pipe flanges. Flange faces shall be faced smooth after flanges have been welded to pipe or flange skirt. Flange skirts shall be a minimum 12 inches long unless stated otherwise. Flanges 24 inches or smaller may be forged flanges conforming to ANSI B16.5 and may be faced prior to welding to pipe unless stated otherwise. Blind flanges shall be Class 300 conforming to ANSI BI6.5, except where indicated otherwise. Reducing flanges are required in order to attach air release valve assemblies and special fittings to nozzles of a larger diameter. The reducing flanges shall be as shown on the Drawings.

5. Flange gaskets shall be- full faced, conforming to the requirements of AWWA C207 and the Drawings.

6. Pipe flanges mating with blind flanges at pumping risers shall be drilled and threaded to accommodate double-end threaded studs in accordance with AWWA C207 and these Specifications. Threads shall be formed by tapping or machining. Double-end threaded studs shall be 8.5 inches long with 3 inches threaded on one end and 3.5 inches threaded on the other end. The stud shall be threaded through the full pipe flange thickness. The assembly shall be secured with nuts tightened on the topside of the blind flange.

7. Unless indicated otherwise, all bolts, studs, and threaded rods shall conform to the requirements of ASTM Standard A193, Grade B7 (125 ksi tensile), or better; All nuts shall be ASTM A194, Grade 2H. Unless indicated otherwise, bolts shall be furnished with semifinished regular hexagon heads and nuts. Unless indicated otherwise, threads shall be Class 2 fit as specified in ANSI Standard B 1.1. Unless indicated otherwise, washers shall be of forged or rolled steel conforming to ANSI/ASTM Standard A3 6.

8. All bolts, tie rods, studs, and- nuts for harness assemblies shall be ANSI/ASTM Standard A325 Type III (or better) unless specifically indicated otherwise on the Drawings. Washers for harness assemblies shall conform to ANSI/ASTM F436. All steel plate for harness assemblies shall be ANSI/ASTM Standard A36 or A572 Grade 36.

E. Lining and Coating Systems. Provide shop-coated and shop-lined steel pipe with minimum of one coat of shop-applied primer approved for use in drinking water transmission on all




exposed steel surfaces. Provide primer compatible with coating system and in accordance with coating manufacturer's recommendations.

1. Internal Linings: Supply steel pipe with cement-mortar lining in accordance with AWWA C205. Provide linings conforming to American National Standards Institute/National Sanitation Foundation (ANSI/NFS) Standard 61, with certification from organization accredited by ANSI.

a. Epoxy Lining: Coat all exposed (wetted) steel parts of flanges, blind flanges, bolts, access manhole covers, etc. with liquid epoxy lining in accordance with AWWA C210 and manufacturer's recommendations.

b. Cement Mortar Lining: In accordance with AWWA C205, except as specified herein: provide 1/2-inch minimum thickness. Cut back lining from joint ends no more than 2 inches to facilitate joining and welding of pipe. Apply cement-mortar lining to inside of pipe by centrifugally spinning. For special sections (shape of which precludes application by spinning method) accomplish by mechanical placement or pneumatic placement and finish to produce smooth, dense surface comparable to centrifugally spinning. Use galvanized wire mesh when shop-applied mortar is not applied by machine. Do not extend wire mesh across welded portion of mitered fittings. Crimp mesh to provide integral "chair" so wire does not fully rest against steel cylinder. Make repairs of cement-mortar lining for widths exceeding 6 inches by bonding to steel and adjacent faces of lining with bonding agent conforming to ASTM C 881, Type II. Restrict usage of sprinkler heads during moist curing to prevent over spraying onto lining. No alternative curing methods are allowed as described in Section 4.4.7.4 of AWWA C205.

2. External Coatings: Supply cement mortar coating for 66-inch water line, and polyethylene coating for 42-inch water line as follows:

a. Cement-mortar Coating: AWWA C205; shop-applied, cement-mortar coating except as modified in this Section; 1-inch minimum thickness; cut back coating from joint ends no more than 2.5 inches for lap and 3" inches for butt-strap to facilitate joining and welding of pipe.

b. Polyethylene Coating: In accordance with AWWA C214 and requirements of this Section; 80-mil

i. Components: Primer, one 20-mil layer of inner-layer tape for corrosion protection and two 30-mil layers of outer-layer tape for mechanical protection.

Contract C700; DU-012, WP01 & DU-013 Ready for Construction

33 11 02 - 6 October 19, 2012 SCVWD Water Pipelines


ii. Use approved filler putty type insulating putty to fill gap and create smooth sloped transition between top of reinforcing plate and pipe, before tape coating is applied.

iii. Primer: Compatible with tape coating, supplied by coating-system manufacturer.

iv. Provide pipe with shop coatings cut back approximately 4 to 4-1/2 inches for joint ends to facilitate joining and welding of pipe, or as recommended by shrink sleeve manufacturer. Taper successive tape layers by 1-inch staggers to facilitate field wrapping and welding of joints.

v. Inner and out tape width: 18 inches

c. Do not expose tape coating to direct sunlight for more than sixty days.

d. Heat Shrink Joint Sleeves for Polyethylene Tape Coating: Canusa Aqua-shield, or equal. For repairs to heat shrink joint sleeves, use Canusa Aqua-shield Repair Kit or equal. Pipe manufacturer to hold back coatings at joints as per shrink sleeve manufacturer's recommendations.

e. All couplings, both flanged and not flanged, shall be fusion bonded epoxy coated and line conforming to AWWA C213 on all surfaces.

3. Field Joints: Field joints shall be coated and lined as shown on the Drawings in accordance with the following requirements:

a. On all cement mortar coated welded steel pipe, the exterior of the joints shall be coated with cement mortar grout consisting of one part Portland cement to two parts of masonry sand by weight and sufficient water to obtain workable consistency. Immediately prior to placing the field-applied cement mortar, the edges of the shop-applied cement mortar coating shall be cleaned and moistened. The grout shall be poured into the diaper from one side only and shall be rodded to eliminate air pockets. The joint coating shall be kept moist until the backfill is placed.

b. A mastic compound shall be applied where required and at all field joints or fittings requiring field tape coatings which have irregular or uneven surfaces. The mastic shall be applied to provide a smooth, regular surface to allow tape coating to be placed without gaps, folds, or air pockets. The mastic compound shall be flexible




and shall be "Ram-Nek" as distributed by Hanson Concrete Products, Inc., 1 Hanson Court, Milpitas, CA 95035, or equal.

c. The exterior of joints of polyethylene coated pipe shall be field coated with a heat shrink joint sleeve conforming to AWWA C216 (submitted to the VTA for approval before field coating). Apply manufacturer-approved insulating putty at bell stepoffs. Apply heat-resistant protective sleeve, such as Canusa Aqua-Shield AQW-WAB or equal, prior to internal welding. Surface preparation: Clean exposed metal with solvent, wire brush, and blast clean in accordance with AWWA C216 and manufacturer's specifications. Apply sleeve in accordance with manufacturer's specifications. Visually inspect sleeve to verify adhesive flows beyond edge, and there are no cracks or holes. Repair as necessary in accordance with AWWA C216 and manufacturer's recommendations. Shrink sleeve manufacturer's technical representative shall be available on site at beginning of pipe laying operations, and advise Contractor and VTA regarding installation, repairs, and general construction methods.

d. In all types of pipe with cement mortar lining, the inside joints shall be mortared by hand and trowel without crumbling. The cement mortar shall conform to that specified above for exterior coating. Before placing the joint cement mortar materials against the surfaces of the lining, these surfaces shall be carefully cleaned and wetted to ensure a good bond between the lining and joint cement mortar. Upon completion of the joint, cement mortar surfaces shall be cured by applying a curing compound conforming to ANSJ/ASTM Standard C309.

F. Flanged Coupling Adapters

1. Design pressure for each coupling shall be as shown on the Drawings and as specified in these Specifications. The installed coupling shall provide a joint with no visible leaks at a test pressure of 1.1 times the design pressure.

2. Materials shall conform to the following:

a. Body sleeve shall be fabricated from steel conforming to ASTM Standard A53, ASTM Standard 512, or equal.

b. Followers shall be fabricated from steel conforming to AISI C1018 or equal.

c. Flanges shall conform to AWWA C207.

d. Bolts and nuts shall meet the minimum physical requirements of ASTM Standard A307, Grade A, or ASTM Standard A325, at the Contractor's option.




e. Gaskets shall be wedge-shaped in cross-section and shall be made from a natural or synthetic rubber compound which is suitable for cold water service. Gaskets and all materials in contact with water shall be NSF 61 approved. Gasket materials shall not contain any asbestos or reclaimed materials and the type of rubber shall have been in general use for sleeve type couplings for at least 10 years. Gaskets shall conform to the following:

• Compression Set: Maximum 4 percent 30 minutes Maximum 3 percent 3 hours

• Compression set shall be determined in accordance with ASTM Standard D395, Method A, except that the discs shall be subjected to pressure of 600 psi for 48 hours at room temperature. Disc shall be 1/2-inch thick with a diameter of 3/4-inch and shall be cut from a 3-inch diameter plaque.

• Indentation Harness by Durometer-75+5 Durometer tests shall be in accordance with ASTM Standard D2240.

f. No flanges shall be tapped.

G. Underground Warning Tape. Underground tape for pipe, including air vent piping, shall be a minimum of 4 mils thick and 6" wide, and shall be inert yellow plastic film designed for prolonged use underground. The tape shall have the words, "CAUTION WATER LINE BELOW", or similar, clearly visible in repeating patterns along its entire length.

2.02 VALVES

A. Combination Air Release Valve Assemblies:

1. The Contractor shall install combination air release valve assemblies consisting of a combination air release valve, gaskets, bolts, nuts, fittings, brackets, extensions, piping, butterfly valves and operators, gate valves, corporation stops, air release valve assemblies, and insulating joints as shown on the Drawings and as specified in this Specification.

2. All exterior surfaces of valves, fittings, bolts and nuts, etc. for combination air release valve assemblies shall be protected with primer and liquid epoxy paint applied in accordance with AWWA C210.

3. Combination air release valves shall be Model No. 154/200, 155/200, or 157/200 "Custom Built" combination air release valves manufactured by APCO Valve and Primer Corporation, Post Office Box 1031, San Mateo, California 94403; Model Nos. 108/45, 110/45, or 114/45 "Custom Built" combination air release valves manufactured by Val-Matic, Pressnell Group/Kipco, 20183 Mack Street, Hayward, California 94545; Model Nos. AL82IPL20, AL10IPL20, or AL142IPL20 "Custom Built" combination air release valves manufactured by Crispin Multiplex Manufacturing Co., 600 Fowler Avenue, Berwick, Pennsylvania 18603; or equal. The body, cover, and baffle of the combination air release valves shall be either cast iron or fabricated steel and be capable of withstanding working pressures up to 200 psi




and surge pressures up to 300 psi. If fabricated steel is used, the interior of the valve shall be fusion-bonded epoxy coated in accordance with AWWA C213. Mesh intake screen shall be provided in the hood assembly. Combination air release valves shall be the size shown on the Drawings. All valves shall be fusion-bonded epoxy lined and coated per AWWA C213 and AWWA C550.

4. Vent piping: Vent piping shall be liquid epoxy lined and coated. Liquid epoxy coating shall conform to AWWA C210 consisting of one coat of a 2-part chemically cured inhibitive epoxy primer and two coats of a 2-part chemically cured coal-tar epoxy finish coat. Unless otherwise specified, coatings and linings of flanges, insulating joints, nuts, bolts, other miscellaneous metals and pipe in vaults and boxes shall be liquid epoxy lined and coated per the requirement specified in above and painted to provide a uniform appearance. Couplings shall be fusion bonded epoxy lined and coated conforming to AWWA C213.

5. Furnish standard rebuild kit for each combination air release valve

B. Flanged butterfly valve: All butterfly valves shall conform to the applicable portions of AWWA C504 for rubber-seated butterfly valves except as modified herein. All butterfly valves shall be of the short-body type with flanged ends. All butterfly valves shall be Class 250 and able to take a maximum nonshock shutoff pressure of 250 psi.

1. The Contractor shall furnish records of all tests specified in AWWA C504 if requested by VTA.

2. All butterfly valves shall be provided with protective coatings conforming to AWWA C550.

3. An affidavit of compliance shall be issued by the manufacturer or vendor as specified in Section 1.7 of AWWA C504.

4. Certified drawings shall be submitted by the Contractor to the VTA for review in accordance with of these Specifications as specified in Sections 1.4 and 1.5 of AWWA C504. Additional drawings or manufacturer's data may also be required.

5. Valve bodies may be constructed of gray iron or ductile iron in accordance with AWWA C504.

6. Valve shafts shall be constructed of Type 304 stainless steel.

7. Valve discs shall be ductile iron with stainless steel edging, fabricated steel with stainless steel edging, or cast stainless steel.

8. Unless indicated otherwise, valve seats shall be mounted in the valve body. On valves 24 inches in diameter and larger, the seats shall be field adjustable and replaceable.

9. Manual operators for butterfly valves shall conform to the requirements of AWWA C504 Section 3.8, except as modified herein. Manual operators for buried service




valves shall be equipped with a 2-inch square AWWA nut on a solid stem extension. The stem extension shall be completely encased in a cast iron, solid pipe with lockable cover and ground level valve position indicator. Legend on the cover shall be "Water". All buried valves shall be equipped with worm-gear operators, lubricated and sealed to prevent entry of dirt or water into the housing.

2.03 CORROSION CONTROL TEST STATIONS

A. Test stations shall be used as a test lead terminal to read:

1. Underground structure-to-soil potentials

2. Cathodic protection anode currents

3. The resistive integrity of the insulating flange and joints

4. The integrity of insulation between all types of underground metallic structures, such as between a carrier and its casing

5. Stray currents on all types of underground structures

B. Unless otherwise specified, all materials and equipment shall be new and shall bear UL approval where UL standards apply. Unless otherwise specified, all work shall conform to the requirements of the National Electric Code. All work shall be done in accordance with all city, county, state, federal and special codes and regulations, these Specifications, and the Drawings.

C. Except where otherwise stated, all cable connections for corrosion control shall be made with alumino-thermic welds and coated as indicated on the Drawings and as specified in these Specifications.

D. Insulating blankets shall be a minimum 1/4- inch thick sheet of butyl rubber, PVC, micarta, neoprene or other similar insulating material as approved by the VTA. Insulating blankets shall be the size as shown on the Drawings or as directed by the VTA.

E. Corrosion Control Test Leads - Corrosion control test leads shall be be No.4 AWG stranded copper with 7/64-inch thick high molecular weight polyethylene (HMWIPE) insulation unless indicated otherwise on the drawings, specifically designed for cathodic protection service and suitable for direct burial in corrosive soil, conforming to ASTM D1248, Type I, Grade J3, Class C, Category 5 (HMWPE Type CP). Each wire shall have at least 18 inches of slack in the test box. Wires with cut or damaged insulation are not acceptable and replacement of the entire lead will be required. Wires shall be sufficient length to extend from the point of installation on the pipeline to the appropriate corrosion monitoring test box without splices.

F. Test Lead Conduit - Nonburied conduit runs and fittings shall be 2-inch galvanized steel, PVC coated, conforming to UL-6, with a minimum 20 mil PVC coating. Unless indicated




otherwise, all buried conduits shall be Schedule 40 high impact PVC. Long radius elbows are required.

G. Concrete Test Boxes - Concrete test boxes shall be precast concrete with a cast iron lid as shown on the Drawings and shall have sufficient strength to support H-20 vehicular traffic. Covers shall be cast with the legend "CP Test", using letters not less than 2 inches high %" thick and %" height. Use Christy Concrete Products, G5 or equal.

H. Terminal Boxes - Terminal boxes shall be 8 inches by 6 inches by 4 inches NEMA Type 3R enclosures and shall include the following:

• A drip shield top. • Hinged door with a pull catch and hasp suitable for padlocking. Hasp shall

include provisions to accept a padlock with a 3/8-inch diameter shank.

1. Terminal block panels inside terminal boxes shall be micarta or laminated phenolic sheets cross laminated for resistance to warpage and weathering. Thickness of panel material shall provide sufficient strength to prevent breakage during shipment. Minimum acceptable thickness for panel is 1/4 inch.

2. Terminal blocks shall be five contacts of Type TS Catalog No. 222 and one end block of Catalog No. 230 manufactured, by Buchanan Electrical Products, Corp., Union, New Jersey 07083 or 600V, T25A No.4 AWG Sterm Type T-5 manufactured by Curtis Developing and Manufacturing Co., 3266 North 33rd Street, Milwaukee, Wisconsin 53216; or equal.

3. Terminal boxes shall include all internal mounting hardware and shunts as indicated on the Drawings and as specified in these Specifications. Mounting hardware, including solderless lug connectors shall be brass or copper alloy.

4. Terminal boxes shall be securely mounted to the vault wall or steel 'channel post with hot-dip galvanized bolts, screws, washers, nuts, conduit straps, etc.

2.04 MONITORING AND DATA LOGGER TEST STATION

A. Provide the monitoring and data logger test station at the location shown on the Drawings. Use the Watchdog P2S-AC manufactured by Elecsys Corporation, or equal.

2.05 REFERENCE ELECTRODES

A. Reference electrodes shall be copper-copper/ sulfate, suitable for direct burial and designed to remain stable for at least 25 years.

B. The reference electrode shall be capable of maintaining a potential within ±10 millivolts of a freshly made cell while draining 3 microamperes. Electrodes shall contain a barrier to inhibit migration of chloride ions from the soil into the reference electrode. Reference electrode lead wire shall be #4 AWG, stranded copper, with HMWPE insulation and shall be silver soldered to the copper core of the reference cell with the connection epoxy sealed by the




manufacturer. Use Stelth 3 Model SRE-010-CPY by Borin Manufacturing Inc., Staperm Model CU-1-UGPC by GMC Electrical Inc., or equal.

2.06 CONNECTORS

A. Split bolts shall be compact, high strength, high copper alloy, have free-running threads and easy to grip wrench flats. Bolts shall have high resistance to resist cracking and corrosion.

2.07 ALUMINO-THERMIC WELD KITS

A. Make the connection of the wire to metallic structure by exothermic weld or by brazing.

B. Exothermic weld material shall be a mixture of copper oxide and aluminum, packaged by size in plastic tubes. The materials shall be non-explosive and not subject to spontaneous ignition.

C. Material of different manufacturers shall not be mixed.

D. Connections shall be made in accordance with UL 486.

E. Connectors and accessories shall be Erico Products, Inc., or equal.

2.08 PIPE FLANGE INSULATING KITS

A. Pipe flange insulating kit materials shall be of the type designated by the manufacturer as suitable for appropriate service at the operating temperatures and pressures specified on the Plans.

B. Flange insulating kits shall consist of a one piece full-face, insulating gasket, an insulating sleeve for each bolt, two insulating washers for each bolt, and a steel washer between each insulating washer and nut.

1. Insulating Gasket: Insulating gasket retainers shall be full-face, Type E, NEMA G-10 epoxy glass retainers with a nitrile (Buna-N) rectangular cross section O-ring sealing. Minimum total thickness shall not be less than 1/8-inch. Dielectric strength shall be not less than 550 volts per mil, and compressive strength of not less than 50,000 psi. Use PSI Linebacker, or equal.

2. Insulating Sleeves: Provide full length, one piece, insulating flange bolt sleeves for the appropriate bolt size. Insulating sleeves shall be NEMA G-10 epoxy glass. Dielectric strength shall be not less than 400 volts per mil.

3. Insulating Washers: Insulating washers shall be NEMA G-10 epoxy glass with a minimum thickness of 1/8-inch. Dielectric strength shall not be less than 550 volts per mil, and compressive strength of not less than 50,000 psi.

4. Provide cadmium plated steel flange bolt washers for placement over the insulating washers with a minimum thickness of 1/8 inch.




2.09 COATINGS FOR BURIED INSULATED PIPE FLANGES

A. The wax-tape coating shall conform to the requirements of AWWA C217, and shall consist of three parts: surface primer, wax-tape and outer covering.

1. The primer shall be a blend of petrolatum, plasticizer and corrosion inhibitors having a paste like consistency such as Trenton Wax-Tape Primer, or equal.

2. The wax-tape shall be a plastic-fiber felt tape, 50 to 70 mils thick, and saturated with a blend of petrolatum, plasticizer, and corrosion inhibitors that is easily formed over irregular surfaces such as Trenton #1 wax-tape, or equal.

3. The outer covering shall be a plastic wrapper consisting of three each 50 gauge, clear polyvinylidene chloride, high cling membranes wound together as a single sheet such as Trenton Poly-Ply, or equal.

2.10 BRASS IDENTIFICATION TAGS

A. All corrosion control test leads shall be identified with 1-inch diameter by 1/16-inch brass tags. Tags shall be securely attached to the test leads with uninsulated No. 14 copper wire. All tags shall be die stamped per the Drawings.

2.11 UNDERGROUND WARNING TAPE

A. Underground warning tape for horizontal runs of buried leads in corrosion control test lead cable trenches shall be a minimum of 4 mils thick and 6 inches wide, and shall be inert red plastic film designed for prolonged use underground. The tape shall have the words, "CAUTION CATHODIC PROTECTION CABLE BELOW," or similar, clearly visible in repeating patterns along its entire length.

2.12 WELD COATING

A. Coating for all corrosion control welds shall be cold-applied, fast drying mastic consisting of bituminous resin and solvents. The minimum percentage of solids shall be 80 percent.

PART 3 - EXECUTION

3.01 TRANSPORTATION AND DELIVERY

A. Pipe shall be strutted, loaded, and transported to minimize cracking of lining and coating in welded steel pipe. Said stmts shall be installed prior to the removal of pipe from the fabrication yard. Struts shall remain in the pipe until after the backfill has been placed to full height and compaction completed so that damage to the pipe coating and/or lining is minimized.

B. The strutted pipe, when backfill is complete, shall have a diametric variation of no greater than plus or minus 0.5 percent. When the struts are removed after the backfilling is complete, the unstrutted pipe shall have a diametric variation of no greater than plus or minus 1.3




percent.

C. The Contractor shall protect all coated surfaces from damage prior to and during erection in accordance with the requirements of Section 4 of AWWA C203 and as specified herein.

D. Except for District-furnished pipe, the Contractor shall load and haul the pipe to the site of the work. During, loading, transportation, and unloading, every precaution shall be taken to prevent damage to the pipe or its coating or lining. Pipe shall be handled only by means of approved hooks on the ends or by means of approved slings. Trucks or trailers used for transporting the pipe shall be provided with padded bolsters curved to fit the outside of the pipe. Padding sufficiently thick and stiff to prevent scoring of coating shall be used under the chains. Coated pipe shall not be placed directly on rough ground. When stored at trench side or elsewhere, coated pipe shall be supported at quarter points by two substantial timber cradles or by two sand ribbons. Rolling the pipe will not be permitted. Any pipe section that becomes damaged shall be repaired at the expense of the Contractor as directed by the VTA if in his opinion a satisfactory repair can be made; otherwise, it shall be replaced with an undamaged section of pipe at the sole expense of the Contractor.

3.02 INSTALLATION OF PIPE

A. All pipe shall be laid to the lines and grades shown on the Drawings. All pipe laying and jointing operations shall conform to the applicable "good practice procedure" requirements as set forth in AWWA Manual Ml 1, and as noted on the Drawings and specified hereinafter. Conduit for the telemetry cable shall be installed with the pipeline in accordance with Section 27 15 01 of these Technical Specifications and as shown on the Drawings.

B. On grades exceeding 10 percent, the pipe shall be laid uphill or otherwise held in place by methods approved by the VTA.

C. Handling of Pipe - All dirt and other foreign matter shall be removed from the pipe barrel and the pipe ends shall be thoroughly cleaned prior to the laying operation. The lifting and lowering of the pipe into the trench shall be accomplished by the use of devices of proper width and design to prevent damage to the pipe, its lining, and coating. The pipe shall not be dragged, pushed, rolled, or otherwise slid into position.

D. Positioning Pipe for Join - Blocking which may be used to assist in the alignment of the pipe during the laying operation shall be placed only at the ends of the pipe section and shall be removed before the adjoining section is placed. The trench shall be carefully graded and the bedding prepared in accordance with Section 33 05 28 of these Technical Specifications. Backfill material shall be placed and compacted around and under the pipe in sufficient quantity and manner to assure proper line and grade while the joint is being made and coated. No backfill shall be placed over the pipe until after the pipe has been inspected and approved by the VTA.

E. Tolerances - All pipes shall be laid to the lines and grades shown on the Drawings. Tolerances for departure from and return to established alignment and grade shall be 1/16-inch per foot of pipe, but not more than 2 inches at any given point in the line, except where




grade changes are made to eliminate special sections or fittings as specified in these Specifications.

F. Pipe Cleaning - At suitable intervals in the progress of the pipe laying operation, after all work inside the pipe has been completed and backfill placed, all debris created by the lining of the joints or other work shall be removed and the entire interior left thoroughly clean.

G. For welded steel pipe, polyethylene sheeting shall be secured over the open end of the cylinder section containing the bulkhead prior to placement of the pipe section into the trench. Polyethylene sheeting shall have a minimum thickness of 4 mils. A 4-foot by 4-foot by 1-inch thick (minimum) plywood sheet shall be placed against the open end prior to backfilling to keep backfill material from contacting the polyethylene covered opening. The plywood sheet shall be left in place.

H. Connections to Existing Pipe - The Contractor shall connect the pipeline to the existing pipeline, as shown on the Drawings and as specified in these Specifications. The connections to the existing pipe shall include making the physical connections, removing bulkheads, and repairing the linings and coatings as shown on the Drawings and as specified in these Specifications.

1. For connection to existing pipe, Contractor shall verify elevation and location of existing pipe in field prior to installation and shall make adjustments as necessary for proper connection at Contractor's sole expense. The Contractor is advised that the existing pipeline may be filled with water and may require draining by the Contractor.

3.03 FIELD TESTING AND REPAIR OF POLYETHYLENE PIPE COATING

A. Immediately prior to lowering the pipe coated with polyethylene into the trench, the Contractor shall conduct an electrical inspection of the polyethylene pipe coating by means of a high voltage holiday detector. The electrical inspection shall be performed in the presence of the VTA. The voltage of the detector shall be adjusted to within 20 percent of the test voltage. The test voltage shall be 12,000 volts for a coating thickness of 80 mils. The optimum travel rate of the holiday detector shall be determined by the Contractor by testing on a tape-wrapped (polyethlene coating) pipe section with a known, pin type holiday. Defective locations shall be clearly indicated by a circular mark or cross immediately upon discovery by visual examination or by the holiday detector.

B. All holidays and minor damaged or defective coating shall be repaired immediately by removing all loose tape and outer tape from the damaged area and removing a rectangular section of the inner tape layer from the holiday area. Apply primer over the rectangular patch area along with a minimum of 4 inches of adjacent inner layer tape on each side of the patch area and completely around the circumference of the pipe. Rewrap the primed area with inner layer material. The affected area shall be retested by the Contractor to determine if the holiday has been repaired successfully. The outer tape layer shall be repaired by replacing the outer tape layer removed with outer tape material and providing a 6-inch overlap over previously applied outer tape wrap. The repair materials and procedures shall be in




accordance with the manufacturer's requirements. The patch tapes and primer shall be the same materials used for manufacture of the pipe.

C. Inspection failure over large areas in any length of pipe, as determined by the VTA, shall be cause for rejection of the length of pipe as unfit and shall be removed immediately from the work site. The Contractor shall be responsible for replacement of rejected pipe at Contractor's expense. No extension of time for completion of the work will be provided due to rejection of pipe. The Contractor shall be responsible for arranging for and providing power as necessary for field testing.

D. Perform electrical inspection on heat shrink joint sleeve to check for holidays.

3.04 CORROSION CONTROL

A. Locations for corrosion control items are approximate and exact placement shall be determined by the Contractor in accordance with structural and mechanical considerations verified in the field. Where conflicts exist, the corrosion control items may be moved with the approval of the VTA.

B. Unless otherwise specified, as-built Drawings for the corrosion control items will be maintained by the VTA during installation and construction. The Contractor shall cooperate and provide assistance as necessary to determine the exact locations of all test leads, test stations, deep anode beds, reference electrodes, conductors, and ornamental rectifier boxes and for the proper identification of all items of equipment and materials installed.

C. Electrical Bonding - Internal electrical bonding is required between all ferrous components of each pipe section; i.e., between ferrous cylinder and wire mesh or reinforcing wire as shown on the Drawings. Electrical bonding using pipe joint bond cables shall be required across all pipe joints except welded and insulating joints.

D. Internal Bonding-Cement Mortar Coated Welded Steel Pipe - Attachments of ends and splices in wire mesh and fabric and reinforcing wire shall be welded

E. Pipe Joint Bond Cables - Pipe joint bond cable assemblies for rubber gasket pipe shall be fabricated as shown on the Drawings.

F. Conductors for pipe joint bond assemblies shall be a rope stranded copper welding cable with a neoprene insulation rated for an operating voltage of at least 125 volts

G. The quantity and size AWG for conductors will vary depending on the class and diameter of pipe. The minimum size of conductors shall be #2 AWG. The Contractor shall provide the number of pipe joint bond assemblies and size of conductors required to comply with the following:

1. The increase in electrical resistance due to the joint bonds per 1,000 feet of pipe does not exceed 250 percent when compared to the electrical resistance of 1,000 feet of welded pipe when calculated as follows:




I = [ l+(Rb/Rp)] x 100

Where:

I = Percent increase in electric resistance Rb = Resistance in ohms of the joint bonds per 1.000 feet of pipe Rp = Resistance in ohms of 1,000 feet of pipe if joints were welded when calculated as follows:

Rp = 0.2170/Wp for steel pipe

Wp = Weight of steep pipe cylinder in pounds per linear foot of pipe

2. Electrical resistance calculations shall be based on the installation of a minimum of two (2) and a maximum of four (4) joint bond assemblies per pipe joint. The Contractor shall provide electrical resistance calculations with the shop drawing submittals for fabricated pipe joint bond cable assemblies.

H. The Contractor, at his option, may submit to the VTA for approval alternate methods of fabricating and attaching pipe joint bond cables. However, these attachments shall be made with appropriate welds and/or alumino-thermic weld processes only. Bolted type mechanical connections shall not be allowed. Pipe joint bonds shall include a flexible insulated copper conductor between points of connection. Steel "Z-bars" or steel rods without the use of flexible insulated copper conductor between points of connection shall not be used.

I. All pipe joint bond connections to pipe bells and spigots shall be coated as shown on the Drawings.

J. Pipe joint bond cable assemblies shall be installed in blockouts as shown on the Drawings. Blockouts shall be provided during the pipe manufacturing. Blockouts shall be filled as shown on the Drawings

K. Corrosion control test station shall be as the following:

1. Four-wire corrosion control test stations at ends of casings and new pipes

2. Two-wire corrosion control test stations at all precast vaults.

L. Corrosion Control Test Leads

1. Wire routing for test leads shall be as shown on the Drawings. Alternate routing from locations shown is acceptable when approved by the VTA.

2. All direct buried test leads shall be installed at a minimum depth of 30 inches below finished grade or as shown on the Drawings. Test leads may be run in or near pipe trenches. The bottom of the finished test lead trench shall be stone-free earth. The test lead trench shall be backfilled in accordance with the requirements of Section 33 05 28, Trenching and Backfilling for Utilities, of these Technical Specifications. Care




shall be taken when installing test leads and backfilling the trench so that insulation is not broken, cut or bruised. If wire insulation is damaged, it shall be replaced at the Contractor's expense.

3. All direct buried test leads that extend to concrete test boxes across the roadway as shown on the Drawings shall be installed in conduit between the pipe wall and the concrete test box.

4. The Contractor shall furnish and install underground warning tape above all conduits for test leads as described above. The underground warning tape shall be a minimum 6 inches wide and 4 mils thick constructed of polyethylene. The tape color shall be red and shall bear the continuously printed nonfading legend:

"Caution Cathodic Protection Cable Below Call SCVWD at 395-8121"

The underground warning tape shall be "Identoline" as manufactured by W. H. Brady, Company, Milwaukee, Wisconsin; "Terra Tape" as manufactured by Reef Industries, Inc., Houston, Texas, or equal.

5. All test leads shall be of sufficient length to reach the termination point at the test or terminal box without splicing; test leads shall not be spliced.

6. All test lead wires terminating in at-grade concrete test boxes shall have sufficient slack to extend a minimum of 18 inches above finish grade.

7. Test leads shall be attached to casing, pipe or valves as shown on the Drawings.

8. All coatings removed for attachment of test leads shall be repaired as indicated. Connections and all exposed copper wire shall be coated with a bitumastic material prior to repairing the coating as indicated.

M. Unless otherwise indicated on the Drawings, top of concrete test boxes shall be set flush with the finished grade.

3.05 FIELD TESTS

A. Welding Tests on Field Welds - Employ an independent certified testing laboratory, approved by VTA, to perform weld acceptance tests on all field welded joints. Tests shall include: 1) fit up visual inspection, 2) root pass visual inspection, 3) cover die penetrate inspection. Furnish copies of test reports to VTA for review. VTA has final decision as to suitability of welds tested.

B. Weld acceptance criteria:

1. Field Lap Joints: Conduct in accordance with ASTM E165-Standard Test Method for Liquid Penetrant Examination or ASTM E709-Standard Guide for Magnetic Particle Examination.




2. Field Butt Welds: Use 100% X-ray method for butt welds in accordance with ASME Boiler and Pressure Vessel Code Section V - Nondestructive Examination.

C. After pipe is joined and prior to start of welding procedure, make spigot and bell essentially concentric by jacking, shimming or tacking to obtain clearance tolerance around periphery of joint except for deflected joints. Furnish each welder employed with a steel stencil for marking welds, so work of each welder can be identified. Mark pipe with assigned stencil adjacent to weld. When welder leaves job, stencil must be voided and not duplicated. Welder making defective welds must discontinue work and leave project site. Welder may return to project site only after recertification.

D. The Contractor shall repair any defects in accordance with AWWA C206 until satisfactory tests are obtained. The Contractor shall provide all apparatus and materials for making the tests, shall drill and tap the necessary holes as shown on the Drawings, perform the test and provide the results to the VTA, and shall plug weld the holes after satisfactory completion of the testing.

E. Hydrostatic field Testing - Refer to Section 33 11 03, Hydrostatic Testing, Disinfection and Bacteriological Testing Procedure. Contractor shall hire an independent laboratory to perform above tests per Section 01 43 00, Quality Assurance and Quality Control, of these Technical Specifications.

F. Contractor shall coordinate SCVWD inspection of field welds, interior mortar lining and other interior inspections, including provision for emergency retrieval team.

3.06 CUTOVER

A. The Contractor shall indicate on the schedule the time period requested for the shutdown. The Contractor shall notify VTA in writing 7 calendar days prior to the requested shutdown period.

B. Prior to the shutdown period, the Contactor shall install and backfill the new pipe and appurtenances, complete field hydrostatic testing, remove bulkheads and repair linings and coatings and complete all work required to put the pipelines back into operation following the connections to existing pipe.

C. Contractor shall monitor potential leakage through boundary valves and be prepared to discharge additional water by pumping or other means.

D. Prior to making the connections, the Contractor shall verify and assure that all necessary materials, equipment and labor are available and ready for the connections. Equipment shall include lighting and power supply. The Contractor shall expose and verify location and elevation of existing pipe and determine if any adjustments will be required to make the connections.

E. Following welding of the joints at the connections, the welds shall be tested, the pipe lining and coating shall be repaired by the Contractor and the pipeline backfilled, all within the 10-


33 11 02 - 2 0 October 19, 2012 SCVWD Water Pipelines


day shutdown period. The Contractor shall complete all work required to make the pipelines operational and to allow SCVWD to operate the pipelines.

F. No other shutdown of the pipelines will be made during this Contract.

3.07 DISINFECTION

A. Refer to Section 33 11 03, Hydrostatic Testing, Disinfection and Bacteriological Testing Procedure.

END OF SECTION 33 11 02



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