26 20 00B Low-Voltage AC Induction Motorsdnhiggins.com/docs/Marco MF System Specifications.pdf ·...

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402499.MF LOW-VOLTAGE JULY 16, 2010 AC INDUCTION MOTORS ©COPYRIGHT 2010 CH2M HILL 26 20 00 - 1

SECTION 26 20 00 LOW-VOLTAGE AC INDUCTION MOTORS

PART 1 GENERAL

1.01 RELATED SECTIONS

A. This section applies only when referenced by a motor-driven equipment specification. Application, horsepower, enclosure type, mounting, shaft type, synchronous speed, and any deviations from this section will be listed in the equipment specification. Where such deviations occur, they shall take precedence over this section.

1.02 REFERENCES

A. The following is a list of standards which may be referenced in this section:

1. American Bearing Manufacturers Association (ABMA): a. 9, Load Ratings and Fatigue Life for Ball Bearings. b. 11, Load Ratings and Fatigue Life for Roller Bearings.

2. Institute of Electrical and Electronics Engineers, Inc. (IEEE): a. 85, Test Procedure for Airborne Sound Measurements on Rotating

Electric Machinery. b. 112, Standard Test Procedures for Polyphase Induction Motors

and Generators. c. 114, Standard Test Procedures for Single-Phase Induction Motors. d. 620, Guide for the Presentation of Thermal Limit Curves for

Squirrel Cage Induction Motors. e. 841, Standard for Petroleum and Chemical Industry – Severe Duty

Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors – up to and Including 500 hp.

3. National Electrical Manufacturers Association (NEMA): a. 250, Enclosures for Electrical Equipment (1,000 Volts

Maximum). b. C50.41, Polyphase Induction Motors for Power Generating

Stations. c. MG 1, Motors and Generators. d. MG 13, Frame Assignments for Alternating Current Integral

Horsepower Induction Motors. 4. National Fire Protection Association (NFPA): 70, National Electrical

Code. (NEC)

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LOW-VOLTAGE 402499.MF AC INDUCTION MOTORS JULY 16, 2010 26 20 00 - 2 ©COPYRIGHT 2010 CH2M HILL

5. Underwriters Laboratories (UL): a. 1, Flexible Metal Conduit. b. 674, Standard for Safety Electric Motors and Generators for use in

Division 1 Hazardous (Classified) Locations. c. 2111, Overheating Protection for Motors.

1.03 DEFINITIONS

A. CISD-TEFC: Chemical industry, severe-duty enclosure.

B. DIP: Dust-ignition-proof enclosure.

C. EXP: Explosion-proof enclosure.

D. ODP: Open drip-proof enclosure.

E. TEFC: Totally enclosed, fan cooled enclosure.

F. TENV: Totally enclosed, nonventilated enclosure.

G. WPI: Open weather protected enclosure, Type I.

H. WPII: Open weather protected enclosure, Type II.

I. Motor Nameplate Horsepower: That rating after any derating required to allow for extra heating caused by the harmonic content in the voltage applied to the motor by its controller.

J. Inverter Duty Motor: Motor meeting all applicable requirements of NEMA MG 1, Section IV, Parts 30 and 31.

1.04 SUBMITTALS

A. Action Submittals:

1. Descriptive information. 2. Nameplate data in accordance with NEMA MG 1. 3. Additional Rating Information:

a. Service factor. b. Locked rotor current. c. No load current. d. Multispeed load classification (e.g., variable torque). e. Adjustable frequency drive motor load classification (e.g.,

variable torque) and minimum allowable motor speed for that load classification.

f. Guaranteed minimum full load efficiency and power factor. 4. Enclosure type and mounting (e.g., horizontal, vertical).

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5. Dimensions and total weight. 6. Conduit box dimensions and usable volume as defined in NEMA MG 1

and NFPA 70. 7. Bearing type. 8. Bearing lubrication. 9. Bearing life. 10. Space heater voltage and watts. 11. Description, ratings, and wiring diagram of motor thermal protection. 12. Motor sound power level in accordance with NEMA MG 1. 13. Maximum brake horsepower required by the equipment driven by the

motor.

B. Informational Submittals:

1. Factory test reports. 2. Manufacturer’s Certificate of Proper Installation. 3. Operation and Maintenance Data: As specified in Section 01 78 23,

Operation and Maintenance Data.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Baldor.

B. Reliance Electric.

C. U.S. Electrical Motors.

2.02 GENERAL

A. For multiple units of the same type of equipment, furnish identical motors and accessories of a single manufacturer.

B. In order to obtain single source responsibility, utilize a single supplier to provide a drive motor, its driven equipment, and specified motor accessories.

C. Meet requirements of NEMA MG 1.

D. Frame assignments in accordance with NEMA MG 13.

E. Provide motors for hazardous (classified) locations that conform to UL 674 and have an applied UL listing mark.

F. Motors shall be specifically designed for the use and conditions intended, with a NEMA design letter classification to fit the application.

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G. Lifting lugs on all motors weighing 100 pounds or more.

H. Operating Conditions:

1. Maximum ambient temperature not greater than 40 degrees C. 2. Motors shall be suitable for operating conditions without any reduction

being required in the nameplate rated horsepower or exceeding the rated temperature rise.

3. Overspeed in either direction in accordance with NEMA MG 1.

2.03 HORSEPOWER RATING

A. As designated in motor-driven equipment specifications.

B. Constant Speed Applications: Brake horsepower of the driven equipment at any head capacity point on the pump curve not to exceed motor nameplate horsepower rating, excluding any service factor.

C. Adjustable Frequency and Adjustable Speed Applications (Inverter Duty Motor): Driven equipment brake horsepower at any head capacity point on the pump curve not to exceed motor nameplate horsepower rating, excluding any service factor.

2.04 SERVICE FACTOR

A. Inverter-duty Motors: 1.0 at rated ambient temperature, unless otherwise noted.

B. Other Motors: 1.15 minimum at rated ambient temperature, unless otherwise noted.

2.05 VOLTAGE AND FREQUENCY RATING

A. System Frequency: 60 Hz.

B. Voltage Rating: Unless otherwise indicated in motor-driven equipment specifications:

Size Voltage Phases

1/2 hp and smaller 115 1

3/4 hp through 400 hp 460 3

450 hp and larger 4,000 3

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C. Suitable for full voltage starting.

D. 100 hp and larger also suitable for reduced voltage starting with 65 or 80 percent voltage tap settings on reduced inrush motor starters.

E. Suitable for accelerating the connected load with supply voltage at motor starter supply terminals dipping to 90 percent of motor rated voltage.

2.06 EFFICIENCY AND POWER FACTOR

A. For all motors except single-phase, under 1 hp, multispeed, short-time rated and submersible motors, or motors driving gates, valves, elevators, cranes, trolleys, and hoists:

1. Efficiency: Premium Efficiency tested in accordance with NEMA MG 1.

2. Power Factor: High Power Factor, guaranteed 0.90 lagging minimum at full load.

2.07 LOCKED ROTOR RATINGS

A. Locked rotor kVA Code F or lower, if motor horsepower not covered by NEMA MG 1 tables.

B. Safe stall time 12 seconds or greater.

2.08 INSULATION SYSTEMS

A. Single-Phase, Fractional Horsepower Motors: Manufacturer’s standard winding insulation system.

B. Motors Rated over 600 Volts: Sealed windings in accordance with NEMA MG 1.

C. Three-Phase and Integral Horsepower Motors: Unless otherwise indicated in motor-driven equipment specifications, Class F with Class B rise at nameplate horsepower and designated operating conditions, except EXP and DIP motors which must be Class B with Class B rise.

D. Motors with Form-Wound Coils: Locked coil bracing system in accordance with NEMA C50.41.

2.09 ENCLOSURES

A. Enclosures to conform to NEMA MG 1.

B. TEFC and TENV: Furnish with a drain hole with porous drain/weather plug.

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C. Explosion-Proof (EXP):

1. TEFC listed to meet UL 674 and NFPA 70 requirements for Class I, Division 1, Group C and D hazardous locations.

2. Drain holes with drain and breather fittings. 3. Integral thermostat opening on excessive motor temperature in

accordance with UL 2111 and NFPA 70. 4. Terminate thermostat leads in terminal box separate from main terminal

box.

D. Dust-Ignition-Proof (DIP):

1. TEFC listed to met UL 674 and NFPA 70 requirements for Class II, Division 1, Group E, F, and G.

2. Integral thermostat opening on excessive motor temperature in accordance with UL 2111 and NFPA 70.

3. Thermostat leads to terminate in a terminal box separate from main terminal box.

E. Submersible: In accordance with Article Special Motors.

F. Chemical Industry, Severe-Duty (CISD-TEFC): In accordance with Article Special Motors.

2.10 TERMINAL (CONDUIT) BOXES

A. Oversize main terminal boxes for all motors.

B. Diagonally split, rotatable to each of four 90-degree positions. Threaded hubs for conduit attachment.

C. Except ODP, furnish gaskets between box halves and between box and motor frame.

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D. Minimum usable volume in percentage of that specified in NEMA MG 1, Section 1, Paragraph 4.19 and NFPA 70, Article 430:

Terminal Box Usable ValuesVoltage Horsepower Percentage

Below 600 15 through 125 500Below 600 150 through 300 275Below 600 350 through 600 225Above 600 All sizes 200

E. Terminal for connection of equipment grounding wire in each terminal box.

2.11 BEARINGS AND LUBRICATION

A. Horizontal Motors:

1. 3/4 hp and Smaller: Permanently lubricated and sealed ball bearings, or regreasable ball bearings in labyrinth sealed end bells with removable grease relief plugs.

2. 1 through 400 hp: Regreasable ball bearings in labyrinth sealed end bells with removable grease relief plugs.

3. Above 400 hp: Regreasable antifriction bearings in labyrinth sealed end bells with removable grease relief plugs.

4. Minimum 100,000 hours L-10 bearing life for ball and roller bearings as defined in ABMA 9 and ABMA 11.

B. Vertical Motors:

1. Thrust Bearings: a. Plate type (Kingsbury) bearing. b. Manufacturer’s standard lubrication 100 hp and smaller. c. Oil lubricated 125 hp and larger. d. Minimum 50,000 hours L-10 bearing life.

2. Guide Bearings: a. Manufacturer’s standard bearing type. b. Manufacturer’s standard lubrication 200 hp and smaller. c. Oil lubricated 250 hp and larger. d. Minimum 100,000 hours L-10 bearing life.

C. Regreasable Antifriction Bearings:

1. Readily accessible, grease injection fittings. 2. Readily accessible, removable grease relief plugs.

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D. Oil Lubrication Systems:

1. Oil reservoirs with sight level gauge. 2. Oil fill and drain openings with opening plugs. 3. Provisions for necessary oil circulation and cooling.

E. Bearing Isolation: Motors rated for inverter duty shall have electrically isolated bearings to prevent stray current damage.

2.12 NOISE

A. Measured in accordance with IEEE 85 and NEMA MG 1.

B. Motors controlled by adjustable frequency drive systems shall not exceed sound levels of 3 dBA higher than NEMA MG 1.

2.13 BALANCE AND VIBRATION CONTROL

A. In accordance with NEMA MG 1, Part 7.

2.14 EQUIPMENT FINISH

A. Protect Motor for Service Conditions:

1. ODP Enclosures: Indoor industrial atmospheres. 2. Other Enclosures: Outdoor industrial atmospheres, including moisture

and direct sunlight exposure.

B. External Finish: Prime and finish coat manufacturer’s standard.

C. Internal Finish: Bore and end turns coated with clear polyester or epoxy varnish.

2.15 SPECIAL FEATURES AND ACCESSORIES

A. Screen Over Air Openings: Stainless steel on motors with ODP, WPI, and WPII enclosures meeting requirements for Guarded Machine in NEMA MG 1, and attached with stainless steel screws.

B. Winding Thermal Protection:

1. Thermostats (for Motors Less than 50 Horsepower): a. Motors whose motor data sheets and/or control diagrams require

thermostats and all motors greater than 10HP shall be provided with thermostats.

b. Bi-metal disk or rod type thermostats embedded in stator windings.

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c. Automatic reset contacts rated 120 volts ac, 5 amps minimum, opening on excessive temperature. (Manual reset shall be provided at motor controller.)

d. Leads extending to separate terminal box for motors 100 hp and larger.

2. Thermistors (for Motors 50 Horsepower and Greater but Less than 300 Horsepower): a. Thermistor embedded in each stator phase winding before

winding dip and bake process. b. In intimate contact with winding conductors. c. Epoxy-potted, solid state thermistor control module mounted in

NEMA 250, Type 4X box on motor by motor manufacturer. d. Individual thermistor circuits factory-wired to control module. e. Control module rated for 120V ac power supply. f. Control module automatically reset contact for external use rated

120 volts ac, 5 amps minimum, opening on abnormally high winding temperature. Manual reset shall be provided at motor controller.

C. Space Heaters:

1. Provide winding space heaters with leads wired out to separate condulet or terminal box.

2. Provide extra hole or hub on motor terminal box as required. 3. Clearly identify heater wire leads at conduit box. 4. Unless shown otherwise, heater shall be suitable for 120V ac supply,

with wattage suitable for motor frame size. 5. Coordinate power requirements of the space heater with the

manufacturer of motor starters or adjustable frequency drive for sizing of the control power transformer.

D. Nameplates:

1. Raised or stamped letters on stainless steel or aluminum. 2. Display motor data required by NEMA MG 1, Paragraph 10.39 and

Paragraph 10.40 in addition to bearing numbers for both bearings. 3. Premium efficiency motor nameplates to also display NEMA nominal

efficiency, guaranteed minimum efficiency, full load power factor, and maximum allowable kVAR for power factor correction capacitors.

E. Anchor Bolts: Provide anchor bolts meeting manufacturer’s recommendations and of sufficient size and number for the specified seismic conditions.

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2.16 SPECIAL MOTORS

A. Requirements in this article take precedence over conflicting features specified elsewhere in this section.

B. Chemical Industry, Severe-Duty (CISD-TEFC):

1. In accordance with IEEE 841. 2. TEFC in accordance with NEMA MG 1. 3. Suitable for indoor or outdoor installation in severe-duty applications

including high humidity, chemical (corrosive), dirty, or salty atmospheres.

4. Motor Frame, End Shields, Terminal Box, and Fan Cover: Cast iron. 5. Ventilating Fan: Corrosion-resistant, nonsparking, external. 6. Drain and Breather Fittings: Stainless steel. 7. Nameplate: Stainless steel. 8. Gaskets between terminal box halves and terminal box and motor frame. 9. Extra slinger on rotor shaft to prevent moisture seepage along shaft into

motor. 10. Double shielded bearings. 11. 125,000 hours minimum L-10 bearing life for direct-connected loads. 12. External Finish: Double-coated epoxy enamel. 13. Coated rotor and stator air gap surfaces. 14. Insulation System, Windings, and Connections:

a. Class F insulation, Class B rise or better at 1.0 service factor. b. Multiple dips and bakes of nonhygroscopic polyester varnish.

15. Service Factor: a. At 40 Degrees C Ambient: 1.15. b. At 65 Degrees C Ambient: 1.00.

16. Safe Stall Time Without Injurious Heating: 20 seconds minimum.

C. Severe-Duty Explosion-Proof: Meet requirements for EXP enclosures and CISD-TEFC motors.

D. Severe-Duty, Dust-Ignition-Proof: Meet requirements for DIP enclosures and CISD-TEFC motors.

E. Multispeed: Meet requirements for speeds, number of windings, and load torque classification indicated in the motor-driven equipment specifications.

F. Inverter Duty Motor:

1. Motor supplied power by adjustable voltage and adjustable frequency drives shall be inverter duty rated.

2. Motor shall be suitable for operation over entire speed range indicated.

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3. Provide forced ventilation where speed ratio is greater than published range for motor being installed.

4. Motor installed in Division 1 hazardous (classified) locations shall be identified as acceptable for variable speed when used in a Division 1 location.

G. Submersible Pump Motor:

1. Manufacturers: a. Reliance Electric. b. ITT Flygt Corp.

2. At 100 Percent Load: Submersible Pump Motors

Horsepower

Guaranteed Minimum Efficiency

Guaranteed Minimum

Power Factor 5 through 10 80 82

10.1 through 50 85 82 50.1 through 100 87 82

Over 100 89 82 3. Insulation System: Manufacturer’s standard Class B or Class F. 4. Motor capable of running dry continuously. 5. Enclosure:

a. Hermetically sealed, watertight, for continuous submergence up to 65-foot depth.

b. Listed to meet UL 674 and NFPA 70 requirements for Class I, Division 1, Group D hazardous atmosphere.

c. Seals: Tandem mechanical. 6. Bearing and Lubrication:

a. Permanently sealed and lubricated, replaceable antifriction guide and thrust bearings.

b. Minimum 15,000 hours L-10 bearing life. 7. Inrush kVA/horsepower no greater than NEMA MG 1 and NFPA 70,

Code F. 8. Winding Thermal Protection:

a. Thermal sensor and switch assembly, one each phase, embedded in stator windings and wired in series.

b. Switches normally closed, open upon excessive winding temperature, and automatically reclose when temperature has cooled to safe operating level.

c. Switch contacts rated at 5 amps, 120V ac. 9. Motor Seal Failure Moisture Detection:

a. Probes or sensors to detect moisture beyond seals. b. Probe or sensor monitoring module for mounting in motor

controller, suitable for operation from 120V ac supply.

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c. Monitoring module with control power transformer, probe test switch and test light, and two independent 120V ac contacts, one opening and one closing when the flux of moisture is detected.

10. Bearing Overtemperature Protection for Motors Larger than 100 hp: a. Sensor on lower bearing housing monitoring bearing temperature. b. Any monitoring relay necessary to provide 120V ac contact

opening on bearing overtemperature. 11. Winding thermal protection, moisture detection, and bearing

overtemperature specified above may be monitored by a single device providing two independent 120V ac contacts, one closing and one opening on malfunction.

12. Connecting Cables: a. Two separate cables, one containing power and grounding

conductors, and the other containing control and grounding conductors.

b. Each cable suitable for hard service, submersible duty with watertight seal where cable enters motor.

c. Length: 30 feet minimum. d. UL 1 listed and sized in accordance with NFPA 70.

H. Inclined Motors:

1. Motors suitable for operation only in horizontal position not acceptable. 2. Bearings designed for thrust imposed by driven equipment and by motor

rotor when motor is in inclined position. 3. Lubrication system designed to provide adequate bearing lubrication

when motor is in inclined position.

2.17 FACTORY TESTING

A. Tests:

1. In accordance with IEEE 112 for polyphase motors and IEEE 114 for single-phase motors.

2. Routine (production) tests on all motors in accordance with NEMA MG 1. Test multispeed motors at all speeds.

3. For energy efficient motors, test efficiency and power factor at 50, 75, and 100 percent of rated horsepower: a. In accordance with IEEE 112, Test Method B, and NEMA MG 1,

Paragraph 12.59. and Paragraph 12.60. b. For motors 500 hp and larger where facilities are not available to

test by dynamometer (Test Method B), determine efficiency by IEEE 112, Test Method F.

c. On motors of 100 hp and smaller, furnish a certified copy of a motor efficiency test report on an identical motor.

4. Provide test reports for polyphase motors100 hp and larger.

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B. Test Report Forms:

1. Routine Tests: IEEE 112, Form A-1. 2. Efficiency and power factor by Test Method B, IEEE 112, Form A-2,

and NEMA MG 1,Table 12-11. 3. Efficiency and power factor by Test Method F, IEEE 112, Forms F-1,

F-2, and F-3. 4. Temperature Test: IEEE 112, Form A-2.

PART 3 EXECUTION

3.01 INSTALLATION

A. In accordance with manufacturer’s instructions and recommendations.

B. Align motor carefully and properly with driven equipment.

C. Secure equipment to mounting surface with anchor bolts.

3.02 MANUFACTURER’S SERVICES

A. Furnish manufacturer’s representative at Site for installation assistance, inspection, equipment testing, and startup assistance for motors larger than 100 horsepower.

B. Manufacturer’s Certificate of Proper Installation.

END OF SECTION

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SECTION 40 99 90 PACKAGE CONTROL SYSTEMS

PART 1 GENERAL

1.01 REFERENCES


1. The Institute of Electrical and Electronics Engineers, Inc. (IEEE): C62.41, IEEE Recommended Practice on Surge Voltages in Low-Voltage AC Power Circuits.

2. Instrumentation, Systems, Automation Society (ISA): S50.1, Compatibility of Analog Signals for Electronic Process Instruments.

3. National Electrical Manufacturers Association (NEMA): a. 250, Enclosures for Electrical Equipment (1,000 Volts

Maximum). b. AB 1, Molded Case Circuit Breakers and Molded Case Switches. c. ICS 2, Industrial Control Devices, Controllers and Assemblies.

4. National Fire Protection Association (NFPA): 70, National Electrical Code (NEC).

5. Underwriters Laboratories Inc. (UL): 508A, Standards for Safety, Industrial Control Panels.

1.02 SYSTEM DESCRIPTION

A. Assemble panels and install instruments, plumbing, and wiring in equipment manufacturer’s factories.

B. Test panels and panel assemblies for proper operation prior to shipment from equipment manufacturer’s factory.

C. Test panels and panel assemblies for proper operation in the field and participate in Performance Acceptance Testing as noted.

1.03 SUBMITTALS

A. Action Submittals:

1. Bill of material, catalog information, descriptive literature, wiring diagrams, and Shop Drawings for components of control system.

2. Catalog information on electrical devices furnished with system. 3. Shop Drawings, catalog material, and dimensional layout drawings for

control panels and enclosures.

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4. Panel elementary diagrams of prewired panels. Include in diagrams control devices and auxiliary devices, for example, relays, alarms, fuses, lights, fans, and heaters.

5. Plumbing diagrams of preplumbed panels and interconnecting plumbing diagrams.

B. Informational Submittals:

1. Programmable Controller Submittals: a. Complete set of user manuals. b. Fully documented PLC program. c. Cross-reference listing.

2. Manufacturer’s list of proposed spares, expendables, and test equipment.

3. Manufacturer’s Certificate of Proper Installation.

1.04 O&M MANUAL SUBMITTALS

A. Hardware:

1. Provide the following: a. Updated versions of all material described under paragraph

Hardware Documentation. b. Component Manufacturers' O&M Manuals: Include manuals to

cover installation, operation, maintenance, troubleshooting, and calibration.

c. List of spare parts and expendables provided and list of spare parts recommended.

B. Software:

1. Provide the following: a. Programming Manuals: Component manufacturers' standard

programming manuals. b. Software Documentation: Provide a final version of the material

called for under Paragraph Software Design Submittal.

1.05 HARDWARE DOCUMENTATION FOR ETHERNET NETWORK CONNECTED PLC’S

A. Provide the following for all elements of the PLC:

1. Block Diagram: A diagram showing all major system components. Identify components by manufacturer and model number. Show interconnecting cables diagrammatically.

2. Bill-of-Materials: A list of all PLC components. Group components by type and include: a. Component manufacturer, model number, and part number.

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b. Component description. c. Quantity supplied. d. Reference to component catalog information.

3. Descriptive Information: Catalog information, descriptive literature, performance specifications, internal wiring diagrams, power and grounding requirements, power consumption, and heat dissipation of all elements of the PLC system. Clearly mark all options and features proposed for this Project.

4. Outline Drawings: Equipment envelope Drawings showing external dimensions, enclosure materials, conduit connections, and installation requirements.

5. Installation Details: Any modifications or further details as may be required to supplement the Purchase Order Documents and adequately define the installation of the PLC elements.

6. Input/Output List: For each I/O point, list point type, tag number of the source or final control element, equipment description, PLC number, PLC terminal identification, rack number, module slot number, and PLC address. Refer to I/O list provided in Article Supplements. Provide I/O list in the format shown in Supplement.

1.06 APPLICATION SOFTWARE FOR ETHERNET NETWORK CONNECTED PLC’S

A. PLC Application Software Development Methodology: The programmable controller system (PLC) is required to communicate over a fiber optic data link with HMI servers to be provided by others and copper Ethernet links to other PLCs provided as part of the package system. It is extremely important that each PLC is programmed in a way that allows elegant data exchange between the HMI, other PLCs, and this PLC. Coordinate data communication with the HMI applications programmer.

1. All control and monitoring features of the package system HMI shall be available over the Plant SCADA control system.

2. PLC shall be programmed using ladder logic. 3. Provide annotated data exchange look up tables and other information to

allow the HMI applications programmer to implement efficient data exchange between HMI and PLC.

B. Coordinate graphic color standards for indications and alarms with the Owner.

C. The data exchange table must be submitted for approval with the Emulation and Data Integration plan.

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D. Software Design Submittal: This submittal shall be a detailed description on the application program. Submit this material during the program development stage. Provide ladder logic programs to implement all functional requirements specified in applicable process specifications. This submittal shall be reviewed by the Contractor, Owner, and Engineer prior to the submittal of the Preliminary Software Documentation.

E. Preliminary Software Documentation: Provide this submittal at least 4 weeks prior to the Factory Test. Here the term "preliminary" refers only to the timing of this submittal, not the level of detail to be provided. This submittal shall be a fully detailed version of all the material described hereinafter under Paragraph O&M Manual, Paragraph Software Documentation, except that the floppy disc copies are not required at this time.

F. Provide format of reports to be generated by HMI using data received from the PLC. Provide any required calculation procedures.

1.07 DELIVERY, STORAGE, AND HANDLING

A. Prior to shipment, include corrosive-inhibitive vapor capsules in shipping containers and related equipment as recommended by capsule manufacturer.

1.08 EXTRA MATERIALS

A. Spares, Expendables, and Test Equipment:

1. Selector Switch, Pushbutton, and Indicating Light: 20 percent, one minimum, of each type used.

2. Light Bulb: 100 percent, 2 minimum, of each type used. 3. Fuse: 100 percent, 5 minimum, of each type used. 4. Surge Suppressors: 20 percent, one minimum, of each type used.

PART 2 PRODUCTS

2.01 SIGNAL CHARACTERISTICS

A. Analog Signals:

1. 4 to 20 mA dc, in accordance with compatibility requirements of ISA S50.1.

2. Unless otherwise specified or shown, use Type 2, two-wire circuits. 3. Transmitters: Load resistance capability conforming to Class L. 4. Fully isolate input and output signals of transmitters and receivers.

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B. Pulse Frequency Signals: dc pulses whose repetition rate is linearly proportional to process variable over 10:1 range. Generate pulses by contact closures or solid-state switches.

1. Power source: Less than 30V dc.

C. Discrete Signals:

1. Two-state logic signals. 2. Utilize 120V ac sources for control and alarm signals extending more

than 500 feet. 120V ac or 24V dc may be used for all other control and alarm signal circuits.

3. Alarm signals shall be normally open, close to alarm isolated contacts rated for 5-ampere at 120V ac and 2-ampere at 30V dc.

2.02 CORROSION PROTECTION

A. Corrosion-Inhibiting Vapor Capsule Manufacturers:

1. Zerust; Model VC. 2. Hoffmann Engineering; Model A-HCI.

2.03 CONTROL PANEL

A. Panel Construction and Interior Wiring: In accordance with the National Electrical Code (NEC), UL 508A, state and local codes, and applicable sections of NEMA, ANSI, and ICECA.

B. Conform to NEMA ratings as specified in individual equipment sections.

C. Minimum Metal Thickness: 14-gauge.

D. NEMA 250, Type 4X Panels: Type 304 stainless steel construction unless otherwise specified.

E. Doors:

1. Three-point latching mechanisms in accordance with NEMA 250 Type 1 and 12 panels with doors higher than 18 inches.

2. For other doors, stainless steel quick release clamps.

F. Cutouts shall be cut, punched, or drilled and finished smoothly with rounded edges.

G. Access: Front, suitable for installation with back and sides adjacent to or in contact with other surfaces, unless otherwise specified.

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H. Temperature Control:

1. Size panels to adequately dissipate heat generated by equipment mounted on or in the panel.

2. Furnish cooling fans with air filters if required to dissipate heat. 3. For panels outdoors or in unheated areas, furnish thermostatically

controlled heaters to maintain temperature above 40 degrees F.

I. Push-to-Test Circuitry: For each push-to-test indicating light, provide a fused push-to-test circuit.

J. Lighting: Minimum of one door switch controlled internal fluorescent lighting package for all panels sized to cover a minimum of 60 percent of panel width.

K. Minimum of one 120-volt GFCI duplex receptacle for panels 12 cubic feet and larger.

L. Finish:

1. Metallic External Surfaces (Excluding Aluminum and Stainless Steel): Manufacturer’s standard gray unless otherwise specified.

2. Internal Surfaces: White enamel.

M. Panel Manufacturers:

1. Hoffman. 2. Rittal.

N. Breather and Drains: Furnish with NEMA 250, Type 4 and 4X panels.

1. Manufacturer and Product: Cooper Crouse-Hinds; ECD Type 4X Drain and Breather; Drain Model ECD1-N4D, Breather Model ECD1-N4B.

2.04 CONTROL PANEL ELECTRICAL

A. UL Listing Mark for Enclosures: Mark stating “Listed Enclosed Industrial Control Panel” per UL 508A.

B. I&C and electrical components, terminals, wires, and enclosures UL recognized or UL listed.

C. Control Panels without Motor Starters:

1. Furnish main circuit breaker and a circuit breaker on each individual branch circuit distributed from power panel.

2. Locate to provide clear view of and access to breakers when door is open. Group on single subpanel. Provide typed directory.

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3. Circuit Breakers: a. Coordinate for fault in branch circuit trips, branch breaker, and

not main breaker. b. Branch Circuit Breakers: 15 amps at 250V ac. c. Provide UL 489 listed breakers. d. Breaker Manufacturers and Products:

1) Square D; Multi 9 series. 2) Eaton; WMT series. 3) Allen-Bradley; 1489-A series.

D. Control Panels with Three-Phase Power Supplies and Motor Starters:

1. Interlock main circuit breaker with panel door. a. Mount logic controls, branch circuit breakers, overload reset

switches, and other control circuit devices. b. Mount operator controls and indications on front access door.

2. Circuit Breakers: a. In accordance with NEMA AB 1. b. 18,000-ampere RMS symmetrical rating, minimum at 480 volts,

unless otherwise specified. c. Breakers, except Motor Branch Breakers: Molded case thermal

magnetic. d. Tripping: Indicate with operator handle position.

3. Magnetic Motor Starters: a. Full voltage, NEMA ICS 2, Class A, Size O minimum. b. Include three-pole bimetallic or eutectic alloy thermal overload

relays sized for each motor. c. Manual reset type with reset button mounted on panel door.

4. Motor Control: 120V ac (except intrinsically safe circuits where applicable). a. Power Control Transformer:

1) Sufficient capacity to serve connected load, including 200VA for duplex outlet plus 100VA (minimum).

2) Limit voltage variation to 15 percent during contact pickup. 3) Fuse one side of secondary winding and ground the other. 4) Furnish primary winding fuses in ungrounded conductors.

5. Power Monitoring Motor Protection Relay: a. Protect three-phase equipment from single phasing, phase

imbalance, or phase reversal. b. Separate, isolated contact outputs to stop motors and activate

alarm light during abnormal conditions. c. Transient Voltage Protection: 10,000 volts. d. Manufacturer and Product: Motor Saver.

402449A.GN1


6. Power Distribution Blocks: Furnish to parallel feed tap on branch circuit protective devices. Do not “leap frog” power conductors.

7. Terminations for Power Conductors: Suitable for use with 75 degrees C wire at full NFPA 70, 75 degrees C ampacity.

E. Wiring:

1. ac Circuits: a. Type: 600-volt, Type MTW stranded copper. b. Size: For current to be carried, but not less than 14 AWG.

2. Analog Signal Circuits: a. Type: 600-volt, Type 2 stranded copper, twisted shielded pairs. b. Size: 18 AWG, minimum.

3. Other dc Circuits. a. Type: 600-volt, Type MTW stranded copper. b. Size: 18 AWG, minimum.

4. Separate analog and other dc circuits by at least 6 inches from ac power and control wiring, except at unavoidable crossover points and at device terminations.

5. Enclose wiring in sheet metal raceways or plastic wiring ducts. 6. Wire Identification: Numbered and tagged at each termination.

a. Wire Tags: Machine printed, heat shrink. b. Manufacturers:

1) Brady PermaSleeve. 2) Tyco Electronics.

F. Wiring Interface:

1. For analog and discrete signal, terminate at numbered terminal blocks. 2. For special signals, terminate power (240 volts or greater) at

manufacturer’s standard connectors. 3. For panel, terminate at equipment on/with which it is mounted.

G. Terminal Blocks:

1. Quantity: a. For external connections. b. Wire spare or unused panel mounted elements to their panels’

terminal blocks. c. Spare Terminals: 20 percent of connected terminals, but not less

than 10. 2. General: Group to keep 120V ac circuits separate from 24V dc circuits.

a. Connection Type: Screw connection clamp. b. Compression Clamp:

1) Hardened steel clamp with transversal grooves penetrating wire strands providing a vibration-proof connection.

402449A.GN1


2) Guides strands of wire into terminal. c. Screws: Hardened steel, captive, and self-locking. d. Current Bar: Copper or treated brass. e. Insulation:

1) Thermoplastic rated for minus 55 to plus 110 degrees C. 2) Two funnel shaped inputs to facilitate wire entry.

f. Mounting: 1) Rail. 2) Terminal block can be extracted from an assembly without

displacing adjacent blocks. 3) End Stops: One at each end of rail, minimum.

g. Wire Preparation: Crimp type ferrule or stripping only. h. Jumpers: Allow jumper installation without loss of space on

terminal or rail. i. Marking System:

1) Terminal number shown on both sides of terminal block. 2) Allow use of preprinted and field marked tags. 3) Terminal strip numbers shown on end stops. 4) Mark terminal block and terminal strip numbers as shown.

3. Spare Fuse Holder: a. Provide spare fuse holder(s) for all enclosures containing fuses. b. Quantity: As required to hold all spare fuses for each enclosure. c. DIN Rail Mountable. d. Manufacturer and Product: Weidmuller, 7914760001 or equal.

4. Terminal Block, 120-Volt Power: a. Rated Voltage: 600V ac. b. Rated Current: 30 amp. c. Wire Size: 22 through 10 AWG. d. Rated Wire Size: 10 AWG. e. Color: Gray body. f. Spacing: 0.25 inch, maximum. g. Manufacturers and Products:

1) Weidmuller. 2) Entrelec; Type M4/6. 3) Phoenix Contact. 4) Allen-Bradley.

5. Terminal Block, Ground: a. Wire Size: 22 through 12 AWG. b. Rated Wire Size: 12 AWG. c. Color: Green and yellow body. d. Spacing: 0.25 inch, maximum. e. Grounding: Ground terminal blocks electrically grounded to the

mounting rail. f. Manufacturers and Products:

1) Weidmuller; 1010100000. 2) Entrelec; Type M4/6.P.

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3) Phoenix Contact. 4) Allen-Bradley.

6. Terminal Block, Blade Disconnect Switch: a. Rated Voltage: 600V ac. b. Rated Current: 10 amp. c. Wire Size: 22 through 12 AWG. d. Rated Wire Size: 12 AWG. e. Color: Gray body, orange switch. f. Spacing: 0.25 inch, maximum. g. Manufacturers and Products:

1) Weidmuller; 7910210000. 2) Entrelec; Type M4/6.SN.T. 3) Phoenix Contact. 4) Allen-Bradley.

7. Terminal Block, Fused, 24V dc: a. Rated Voltage: 600V dc. b. Rated Current: 6.3 amp. c. Wire Size: 22 through 12 AWG. d. Rated Wire Size: 12 AWG. e. Color: Gray body. f. Fuse: 5 by 20 GMA fuses. g. Fuse Marking: Fuse amperage rating shown on top of terminal

block. h. Indication: LED diode 24V dc. i. Leakage Current: 5.2 mA, maximum. j. Spacing: 0.32 inch, maximum. k. Manufacturers and Products:

1) Weidmuller 1880410000. 2) Entrelec; Type M10/13T.SFL. 3) Phoenix Contact. 4) Allen-Bradley.

8. Terminal Block, Fused, 120V ac: a. Rated Voltage: 600V ac. b. Rated Current: 6.3 amp. c. Wire Size: 22 through 12 AWG d. Rated Wire Size: 12 AWG. e. Color: Gray body. f. Fuse: 5 by 20 GMA fuses. g. Fuse Marking: Fuse amperage rating shown on top of terminal

block. h. Indication: Neon lamp 110V ac. i. Leakage Current: 1.8 mA, maximum. j. Spacing: 0.32 inch, maximum

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k. Manufacturers and Products: 1) Weidmuller 1880420000. 2) Entrelec; Type M10/13T.SFL. 3) Phoenix Contact. 4) Allen-Bradley.

H. Grounding:

1. Internal copper grounding bus for ground connections on panels, consoles, racks, and cabinets.

2. Furnish and install door grounding kit for enclosures. 3. Ground all DIN rail. 4. Ground all components in accordance with manufacturer’s instructions. 5. Ground surge suppressors with shortest possible ground conductor

length. 6. Ground bus grounded at a common signal ground point in accordance

with National Electrical Code requirements. 7. Coordinate ground connection for control panels with Electrical

Contractor. 8. Single Point Ground for Each Analog Loop:

a. Locate signal ground at dc power supply for loop. b. Use to ground wire shields for loop. c. Ground terminal block rails to ground bus.

I. Relays:

1. General: a. Relay Mounting: Plug-in type socket. b. Relay Enclosure: Provide dust cover. c. Socket Type: Screw terminal interface with wiring. d. Socket Mounting: Rail. e. Furnish holddown clips.

2. Control Circuit Switching Relay, Nonlatching: a. Type: Compact general purpose plug-in. b. Contact Arrangement: 2 Form C contacts. c. Contact Rating: 10A at 28V dc or 240V ac. d. Contact Material: Silver cadmium oxide alloy. e. Coil Voltage: As noted or shown. f. Coil Power: 1.8 watts (dc), 2.7VA (ac). g. Expected Mechanical Life: 10,000,000 operations. h. Expected Electrical Life at Rated Load: 100,000 operations. i. Indication Type: Neon or LED indicator lamp. j. Push-to-test button.

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k. Manufacturers and Products: 1) Weidmuller; Riderseries II. 2) Potter and Brumfield; Series KUP. 3) IDEC.

3. Control Circuit Switching Relay, Latching: a. Type: Dual coil magnetic latching relay. b. Contact Arrangement: 2 Form C contacts. c. Contact Rating: 10A at 28V dc or 120V ac. d. Contact Material: Silver cadmium oxide alloy. e. Coil Voltage: As noted or shown. f. Coil Power: 2.7 watts (dc), 5.3VA (ac). g. Expected Mechanical Life: 500,000 operations. h. Expected Electrical Life at Rated Load: 50,000 operations. i. Manufacturers and Products:

1) Potter and Brumfield; Series KUL . 2) IDEC; Series RR2KP.

4. Control Circuit Switching Relay, Time Delay: a. Type: Adjustable time delay relay. b. Contact Arrangement: 2 Form C contacts. c. Contact Rating: 10A at 240V ac. d. Contact Material: Silver cadmium oxide alloy. e. Coil Voltage: As specified or shown. f. Operating Temperature: Minus 10 to 55 degrees C. g. Repeatability: Plus or minus 2 percent. h. Delay Time Range: Select range such that time delay setpoint fall

between 20 to 80 percent or range. i. Time Delay Setpoint: As specified or shown. j. Mode of Operation: As specified or shown. k. Adjustment Type: Integral potentiometer with knob external to

dust cover. l. Manufacturers and Products:

1) Weidmuller; 8647700000. 2) Potter and Brumfield:

a) Series CB for 0.1 second to 100 minute delay time ranges.

b) Series CK for 0.1 to 120 second delay time ranges. 3) IDEC.

J. Programmable Controllers:

1. General: a. Provide PLCs meeting the following minimum requirements

unless otherwise noted in specific package Specification sections.

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b. Function: Used for process monitoring and control by emulating functions of conventional panel mounted equipment such as relays, timers, counters, current switches, calculation modules, PID controllers, stepping switches, and drum programmers.

c. Type: Microprocessor based device programmable using ladder logic.

d. Parts: Central processing unit (CPU), power supply, local and remote input/output modules, local and remote base (chassis/rack) controllers, I/O bases (chassis/rack), data highway, and factory assembled interconnecting cables. Provide components required to make a complete and totally operational system.

2. Environmental: a. Temperature: Operating range 32 to 120 degrees F (0 to

50 degrees C). b. Humidity: Operating range 5 to 95 percent noncondensing. c. Vibration:

1) Sinusoidal: IEC 68-2-6, Test Fc; 0.15 mm peak-to-peak, 10-to 57-Hz; 1 g, 57- to 150-Hz.

2) Random: IEC 68-2-34, Test Fdc; 0.4 g2/Hz, 80- to 350-Hz, and 3dB/octave rolloff, 80- to 20-Hz and 350- to 2-KHz at 10 min/axis.

d. Noise: IEC 801, Part 3, Level 3 and Part 4, Level 3; MIL STD-461B.

e. Isolation: User-side to PLC side 1,500V rms. 3. Central Processing Unit (CPU):

a. Type: Microprocessor, 16-bit minimum. b. Scan Time: Less than 1 ms/K words of relay ladder logic. c. PLC Communications:

1) Minimum 1 serial or Ethernet communication port for communication with a PC or programmer.

d. Instruction Set: 1) Timers and Counters: minimum 256, minimum timer

resolution 0.1 seconds; minimum counter count range 0 to 32,000.

2) Math: Signed integer and floating-point math including add, subtract, multiply, divide, square root, and compare.

3) Register Operations: Shift registers, bit shift, bit set, bit clear, data move and data format conversion.

4) Process Loop Control: User configurable direct or reverse acting PID loop control computation with the capability of both AUTO and MANUAL modes of operation, remote access to controller tuning constants; minimum of 16 PID loops.

5) Real Time Clock: Date and time set and compare.

402449A.GN1


e. Diagnostics: 1) Indicators: Battery status, PLC status, PLC operation mode,

remote I/O communication status. 2) Status Word: With failure status for PLC battery, scan

overrun, communications, I/O, special functions. 3) Power Up: PLC checks status of PROMs upon power up;

runs self-diagnostics on power-up; periodically runs self-diagnostics while in RUN mode, halts logic processor and sets outputs to configured state if fatal error is detected.

4) Diagnostic Tables: Tables, displayable by programming computer, that describe nature and location (address) existing faults and errors.

f. Agency Approvals and Standards: 1) UL listed. 2) CSA certified. 3) DIN Standard 41494. 4) IEC-65A/WG6 draft proposal. 5) Factory Mutual approved.

4. Random Access Memory (RAM): a. Type: CMOS type. b. Word Size: 16 bits, minimum. c. Battery Backup: 1 month, minimum. d. Memory Size: Sufficient to implement all applications software. e. Memory Size: 8 K words of ladder logic memory, 2 K words of

variable memory, plus required overhead for standard functions. f. Read only memory (ROM) for controller’s operating system and

diagnostics. 5. Power Supply: One unit for each input/output base assembly:

a. Voltage: 120/220 volts (user selectable) or 24Vdc, 60-Hz input. 6. Input/Output: Complete input/output system.

a. Discrete Input Modules: 1) Voltage:

a) 120 volts, 60-Hz. b) 24 volts dc.

2) Operating Power: 2 watts. 3) Points per Module: 16 maximum. 4) LED status indicator for each point. 5) Isolation: Between input point and PLC, 1,500 volts rms.

b. Discrete Output Modules: 1) Voltage: 24 volts dc. 2) Operating Power: 2 watts. 3) Load Rating: 2 amps continuous. 4) Isolation: Between PLC and output point, 1,500 volts rms. 5) Points per Module: 16 maximum. 6) LED status indicator for each point. 7) Wire each output to interposing relay.

402449A.GN1


c. Analog Input/Output Modules: 1) Voltage: 24 volts dc. 2) Power: 3 watts. 3) Differential Analog Points Per Module: 8 maximum. 4) Isolated Analog Output Points Per Module: 8 maximum. 5) Isolation: Between PLC and I/O point and between I/O

points, 1,500 volts rms. d. Pulse Input Modules:

1) Input Voltage: 5V or 12-24V (user selectable). 2) Input Current: 7 mA at 5V; 7.0 to 1.5 mA at 12-24V. 3) Points per Module: 4, maximum. 4) Maximum Input Frequency: 100 KHz in counter mode. 5) Maximum Count Value: 0-999,999 (programmable).

7. Identification: Nameplates installed above/below each PLC component (CPU, I/O rack, power supply).

8. Manufacturers: a. Koyo; DirectLogic. b. Or Owner and Engineer approved equal.

K. Front-of-Panel Devices Used in Conjunction with NEMA 250, Type 4X Panels:

1. Potentiometer, Watertight: a. Three-terminal, heavy-duty NEMA 250, Type 4X watertight

construction, resolution of 1 percent and linearity of plus or minus 5 percent.

b. Single-hole, panel mounting accommodating panel thicknesses between 1/8 and 1/4 inch.

c. Include engraved legend plates with service markings. d. Manufacturer and Product: Allen-Bradley; Bulletin 800H.

2. Indicating Lights, Watertight: a. Heavy-duty, push-to-test type, NEMA 250, Type 4X watertight,

industrial type with integral transformer for 120V ac applications and corrosion-resistant service.

b. Screwed on prismatic lenses and factory engraved legend plates for service legend.

c. Manufacturers and Products: 1) Square D; Type SK. 2) Allen-Bradley; Type 800H.

3. Pushbutton, Momentary, Watertight: a. Heavy-duty, NEMA 250, Type 4X watertight, industrial type with

momentary contacts rated for 120V ac service at 10 amperes continuous and corrosion-resistant service.

b. Standard size, black field, legend plates with white markings for service legend.

402449A.GN1


c. Manufacturers and Products: 1) Square D; Type SK. 2) Allen-Bradley; Type 800H.

4. Selector Switch, Watertight: a. Heavy-duty, NEMA 250, Type 4X watertight, industrial type with

contacts rated for 120V ac service at 10 amperes continuous and corrosion-resistant service.

b. Standard size, black field, legend plates with white markings, for service legend.

c. Operators: Black knob type. d. Single-hole mounting, accommodating panel thicknesses from

1/16 to 1/4 inch. e. Manufacturer and Products:

1) Square D; Class 9001, Type SK. 2) Allen-Bradley; Type 800H.

2.05 INSTRUMENT TAG NUMBERS

A. Provide manufacturer’s standard tagging unless otherwise shown on the Drawings.

2.06 NAMEPLATES, NAMETAGS, AND SERVICE LEGENDS

A. Nametags: Permanently mounted bearing entire ISA tag number.

1. Panel Mounted: Plastic, mounted to instrument behind panel face. 2. Field Mounted: Engraved Type 316 stainless steel, 22-gauge minimum

thickness, attached with stainless steel.

B. Service Legends (Integrally Mounted with Instrument) and Nameplates:

1. Engraved, rigid, laminated plastic type with adhesive back. Furnish service legends and nameplates to adequately describe functions of panel face mounted instruments.

2. Color: White with black letters. 3. Letter Height: 3/16 inch. 4. For each panel, face mounted laminated nameplate inscribed with the

panel name and tag number. Color shall be white with black letters 1/2-inch high.

C. Standard Light Colors and Inscriptions: Unless otherwise specified in individual equipment specifications, use the following color code and inscriptions:

Tag Inscription(s) Color

ON ON Red

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Tag Inscription(s) Color

OFF OFF Green

OPEN OPEN Red

CLOSED CLOSED Green

LOW LOW Amber

FAIL FAIL Amber

HIGH HIGH Amber

AUTO AUTO White

MANUAL MANUAL Yellow

LOCAL LOCAL White

REMOTE REMOTE Yellow

FORWARD FORWARD Red

REVERSE REVERSE Blue

1. Lettering: Black on white and amber lenses; white on red and green lenses.

2. Standard Pushbutton Colors and Inscriptions: a. Use following unless otherwise noted:

Tag Function Inscription(s) Color

OO ON OFF

Black Black

OC OPEN CLOSE

Black Black

OCA OPEN CLOSE AUTO

Black Black Black

OOA ON OFF

AUTO

Black Black Black

MA MANUAL AUTO

Black Black

SS START STOP

Black Black

RESET RESET Black

402449A.GN1


Tag Function Inscription(s) Color

EMERGENCY STOP

EMERGENCY STOP

Red

b. Lettering Color: 1) Black on white and yellow buttons. 2) White on black, red, and green buttons.

2.07 ELECTRICAL SURGE AND TRANSIENT PROTECTION

A. Equip control panels with surge-arresting devices to protect equipment from damage as a result of electrical transients induced in interconnecting lines from lightning discharges and nearby electrical devices.

B. Suppressor Locations:

1. Provide at all Control Panel 480Vac and 120Vac power feeds. 2. At point of connection between an equipment item, including ac

powered transmitters, and power supply conductor (direct-wired equipment).

3. On analog pairs at each end when the pair travels outside of building. 4. In other locations where equipment sensitivity to surges and transients

requires additional protection beyond that inherent to design of equipment.

C. Suppressor Design:

1. Construction: First-stage, high-energy metal oxide varistor and second-stage, bipolar silicon avalanche device separated by series impedance; includes grounding wire, stud, or terminal.

2. Response: 5 nanoseconds maximum. 3. Recovery: Automatic. 4. Temperature Range: Minus 20 degrees C to plus 85 degrees C. 5. Enclosure Mounted: Encapsulated inflame retardant epoxy.

D. Suppressors on 120V ac Power Supply Connections:

1. Occurrences: Tested and rated for a minimum of 50 occurrences of IEEE C62.41 Category B test waveform.

2. First-Stage Clamping Voltage: 350 volts or less. 3. Second-Stage Clamping Voltage: 210 volts or less. 4. Power Supplies for Continuous Operation:

a. Four-Wire Transmitter or Receiver: Minimum 5 amps at 130V ac. b. All Other Applications: Minimum 30 amps at 130V ac.

402449A.GN1


E. Suppressors on Analog Signal Lines:

1. Test Waveform: Linear 8-microsecond rise in current from 0 amp to a peak current value followed by an exponential decay of current reaching one-half the peak value in 20 microseconds.

2. Surge Rating: Tested and rated for 50 occurrences of 2,000-amp peak test waveform. a. dc Clamping Voltage: 20 percent to 40 percent above operating

voltage for circuit. b. dc Clamping Voltage Tolerance: Plus or minus 10 percent. c. Maximum Loop Resistance: 18 ohms per conductor.

F. Manufacturers and Products:

1. Panel Mounted on Analog Signals Lines: Emerson/Edco PC-642 series or Phoenix Contact PLUGTRAB series.

2. Panel Mounted on 120V ac Lines: Emerson/Edco HSP-121. 3. Panel Mounted on 480-Volt, Three-Phase Power Supplies:

Emerson/Liebert PowerSure Panel LPM/IM. 4. Field Mounted at Two-Wire Instruments:

a. Encapsulated in stainless steel pipe nipples. b. Emerson/Edco SS64 series.

5. Field Mounted at Four-Wire Instruments: all in NEMA 4X enclosure. a. Enclosure:

1) NEMA 4X Polycarbonate with door. 2) Maximum Size: 12 inches by 12 inches by 8 inches deep.

b. Emerson/Edco; SLAC series.

G. Grounding:

1. Coordinate enclosure grounding and surge suppressor grounding in field panels and field instrumentation with Division 26, Electrical, and suppressor manufacturer’s requirements.

2. Provide control panels with an integral copper grounding bus for connection of suppressors and other required instrumentation and equipment.

3. Provide control panels with door grounding kit. 4. Ground all equipment in accordance with manufacturer’s instructions.

PART 3 EXECUTION

3.01 ELECTRICAL POWER AND SIGNAL WIRING

A. Restrain control and signal wiring in control panels by plastic ties or ducts. Secure hinge wiring at each end so bending or twisting will occur around the longitudinal axis of wire. Protect bend area with a sleeve.

402449A.GN1


B. Arrange wiring neatly, cut to proper length, and remove surplus wire. Install abrasion protection for wire bundles passing through holes or across edges of sheet metal.

C. Use manufacturer’s recommended tool with sized anvil for crimp terminations. No more than one wire may be terminated in a single crimp lug. No more than two lugs may be installed on a single screw terminal.

D. Do not splice or tap wiring except at device terminals or terminal blocks.

3.02 PROTECTION

A. Protect enclosures and other equipment containing electrical, instrumentation and control devices, including spare parts, from corrosion through the use of corrosion-inhibiting vapor capsules.

B. During Work, periodically replace capsules in accordance with capsule manufacturer’s recommendations. Replace capsules at Substantial Completion.

3.03 SOURCE QUALITY CONTROL

A. General:

1. Contractor, Engineer, and Owner may actively participate in many of the tests.

2. Engineer and Owner reserve right to test or retest specified functions. 3. Engineer’s or Owner’s decision will be final regarding acceptability and

completeness of testing. 4. Procedures, Forms, and Checklists:

a. Except for Unwitnessed Factory Test, conduct tests in accordance with, and documented on, Engineer accepted procedures, forms, and checklists.

b. Describe each test item to be performed. c. Have space after each test item description for sign off by

appropriate party after satisfactory completion. 5. Required Test Documentation: Test procedures, forms, and checklists

signed by the Engineer. 6. Conducting Tests:

a. Provide special testing materials and equipment. b. Wherever possible, perform tests using actual process variables,

equipment, and data. c. If not practical to test with real process variables, equipment, and

data provide suitable means of simulation. d. Define simulation techniques in test procedures.

402449A.GN1


e. Test Format: Cause and effect. 1) Person conducting test initiates an input (cause). 2) Specific test requirement is satisfied if correct result (effect),

occurs. 7. Test Plan:

a. Provide a test plan outlining test procedures, descriptions, and checklists. An Engineer approved test plan is a pre-requisite to scheduling a factory test.

B. General Factory Test Requirements:

1. Provide factory test of all Package Control system components before shipment to the Site.

2. Contractor, Engineer, and Owner reserve the right to actively participate in and witness Factory Testing.

3. Notify Contractor, Engineer, and Owner of Factory Testing 3 weeks in advance.

4. Provide testing in accordance with general testing procedures listed above and as noted.

5. Test the following control system features as a minimum: a. Wiring from field and panel devices to the PLC. b. Signal inputs and outputs from the PLC. c. PLC control strategies. d. Interface with Operator interface and front of panel controls. e. Simulate inputs and outputs for primary elements, final control

elements, and panels excluded from test. f. Interface with PICS control system for Ethernet Connected

Package Control Systems. 6. Provide test documentation to the Engineer and Owner.

C. Membrane Filtration System Factory Demonstration Test (FDT):

1. Notify Contractor, Engineer, and Owner of test schedule 3 weeks prior to start of test.

2. Scope: Test entire PLC control system to demonstrate it is operational. 3. Location: Membrane Filtration System Supplier’s facility. 4. Correctness of wiring from panel field terminals to PLC system

input/output points and to panel components. a. Simulate each discrete signal at terminal strip. b. Simulate correctness of each analog signal using current source.

5. Operation of communications between PLCs and Ethernet connected instrumentation and between PLCs and computers.

402449A.GN1


6. Emulation of data exchange over Ethernet of the PLC control system and the PICS HMI/PLC control system. Show that the Membrane Filtration System PLC control system is set up prior to shipment for communication and data exchange with the PICS HMI/PLC control system including coordination of HMI graphic displays.

7. Functional Requirements: Demonstrate Membrane Filtration System Equipment meets the functional requirements outlined in Section 46 61 34, Membrane Filtration Equipment.

8. Correct deficiencies found and complete prior to shipment to Site. 9. Failed Tests: Repeat and witnessed. 10. Make following documentation available to Contractor, Engineer, and

Owner at test site both before and during FDT: a. Drawings, Specifications, Addenda, and Change Orders. b. Master copy of FDT procedures. c. List of equipment to be tested including make, model, and serial

number. d. Approved hardware Shop Drawings for equipment being tested.

11. Daily Schedule for FDT: a. Begin each day with meeting to review day’s test schedule. b. End each day with each meeting to review day’s test results and to

review or revise next day’s test schedule.

3.04 FIELD QUALITY CONTROL

A. Coordination of data exchange with PICS supplier prior to Field Testing:

1. Membrane Filtration System: a. Provide PICS subcontractor with a listing of all I/O available over

Ethernet and the corresponding addresses. b. Provide details in initiating communications and any required

handshaking. c. Provide support to PICS subcontractor during initial Ethernet I/O

shakedown: minimum of one 8 hour day. d. Correct any Ethernet I/O communication errors found to be the

problem of improper configuration of package system supplied components.

e. Schedule: To be coordinated during construction prior to Factory Testing.

B. Field Testing Prior to Facility Startup:

1. Membrane Filtration System Integration Testing: a. Participate in PICS Performance Tests Prior to Facility Startup. b. Prepare Membrane Filtration System PLC, instruments, and

equipment for testing.

402449A.GN1


c. Participate in testing, correcting any interface problems due to Membrane Filtration System Ethernet Connected Equipment, HMI, or PLC programming.

d. Schedule: To be completed once PICS Functional Testing is complete.

C. Performance Acceptance Testing (PAT) During and After Facility Startup:

1. Membrane Filtration System Services: a. Participate in PICS Performance Tests During and After Facility

Startup. b. Prepare Membrane Filtration System PLC, instruments, and

equipment for testing. c. Participate in testing, correcting any interface problems due to

Membrane Filtration System Ethernet Connected Equipment, HMI, or PLC programming.

END OF SECTION

402499A.GN1

402499.MF PUMPS—GENERAL JULY 16, 2010 44 42 56 - 1 ©COPYRIGHT 2010 CH2M HILL

SECTION 44 42 56 PUMPS—GENERAL

PART 1 GENERAL

1.01 REFERENCES

A. The following is a list of standards which may be applicable to all pumps and pumping equipment:

1. American Iron and Steel Institute (AISI): a. Type 416 Stainless Steel. b. Type 316 Stainless Steel. c. Type 1035 Steel. d. Type 4140 Alloy Steel. e. Type 1045 Carbon Steel.

2. American Petroleum Institute (API): a. 610, Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and

Gas Industry Services. b. 670, Machinery Protection Systems.

3. Anti Friction Bearing Manufacturers Association (AFBMA): a. ANSI/AFBMA 9, Standard for Load Ratings and Fatigue Life for

Ball Bearings. b. ANSI/AFBMA 11, Standard for Load Ratings and Fatigue Life

for Roller Bearings. 4. ASTM International (ASTM):

a. A48, Standard Specification for Gray Iron Castings. b. A53, Standard Specification for Pipe, Steel, Black and Hot-

Dipped, Zinc-Coated, Welded and Seamless. c. A276, Standard Specification for Stainless and Heat-Resisting

Steel Bars and Shapes. d. A576, Standard Specification for steel Bars, Carbon, Hot-

Wrought, Special Quality. e. B62, Standard Specification for Composition Bronze or Ounce

Metal Castings. f. B148, Standard Specification Aluminum-Bronze Sand Castings. g. B584, Standard Specification for Copper Alloy Sand Castings for

General Applications. 5. Hydraulic Institute Standards (HIS):

a. 1.6, Standard for Centrifugal Pump Tests. b. 2.6, Standard for Vertical Pump Tests. c. 9.6.4, Vibration Measurements and Allowable Values for

Centrifugal and Vertical Pumps. 6. Institute of Electrical and Electronics Engineers (IEEE): 112, Standard

Test Procedure for Polyphase Induction Motors and Generators.

402499A.GN1

PUMPS—GENERAL 402499.MF 44 42 56 - 2 JULY 16, 2010 ©COPYRIGHT 2010 CH2M HILL

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

1.02 DEFINITIONS

A. Terminology pertaining to pumping unit performance and construction shall conform to the ratings and nomenclature of the Hydraulic Institute Standards, latest edition.

1.03 SUBMITTALS

A. Shop Drawing Submittals:

1. Pump name, identification number, and specification section number. 2. Make, model, and weight of each equipment assembly. 3. Complete catalog information, descriptive literature, Supplier’s

specifications, and identification of materials of construction. 4. Performance data curves showing head, capacity, horsepower demand,

NPSH required, and pump efficiency over the entire operating range of the pump. The equipment supplier shall indicate separately the head, capacity, horsepower demand, overall efficiency, and minimum submergence required at the design flow conditions and the maximum and minimum flow conditions. A family of performance curves at intervals of 100 rpm, unless otherwise specified, from minimum speed to maximum speed, shall be provided for each adjustable speed centrifugal pump. Indicate on the performance curves, the limits recommended for stable operation without surge, without damaging cavitation, and without vibration in excess of the specified allowable vibration limits.

5. Where required by each pump specification section, submit estimated maximum reverse runaway speed for the pump and motor assembly. The coincident reverse flow and pump head shall also be submitted with the speed estimates.

6. Where required by each pump specification section, submit vibration monitoring system including technical product bulletins and descriptions, specification data sheets, wiring diagrams, communications hardware and software, documentation sufficient for configuration of functions specified herein and shown on the Drawings.

7. Detailed structural, mechanical, and electrical drawings showing the equipment dimensions, size, and location of connections and weights of associated equipment.

8. Assembly and installation drawings including shaft size, seal, coupling, bearings, anchor bolt plan, part nomenclature, material list, outline dimensions, and shipping weights.

9. Calculations of seismic response of the pump and motor assembly. Seismic loading and stress shall be included in the pump and motor

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assembly and anchor bolt design analysis. Seismic design criteria shall be as specified in Section 01 60 00, Material and Equipment.

10. Data, in accordance with Section 26 20 00, Motors, for each electric motor.

11. Shipping, storage, and protection, and handling instructions. 12. Supplier’s printed installation instructions. 13. Suggested spare parts list. Include a list of special tools required for

checking, testing, parts replacement, and maintenance with current price information.

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

15. Operational and maintenance data as specified in Section 01 78 23, Operation and Maintenance Data.

16. Supplier’s signed, dated, and certified factory test data report for each pump system which requires factory testing, submitted before shipment of equipment.

17. Supplier’s certification of proper installation. 18. Supplier’s certification of satisfactory field testing.

PART 2 PRODUCTS

2.01 GENERAL

A. A single pump Supplier shall be made responsible for furnishing the pump, motor, and for coordination of design, assembly, testing, and for compliance with the requirements of each pump section. Each pump shall be produced and assembled by the Supplier at a facility owned or operated by the Supplier and under the direct supervision and control of the Supplier.

B. All centrifugal pumps shall have a continuously rising head curve from maximum to minimum specified flows. In no case shall the required horsepower at any point on the performance curve exceed the rated horsepower of the motor or engine, or require operation at a service factor greater than 1.0.

C. No damaging cavitation will be allowed for pumps operating within the stable operating range for the specified operating conditions.

D. Each unit of pumping equipment shall incorporate all required components, coupling, electric motor, appurtenances and necessary mountings.

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E. Dynamically balance rotating parts of each pump and its driving unit before final assembly.

1. Limits: a. Driving Unit Alone: Less than 80 percent of NEMA MG 1 limits. b. Complete Rotating Assembly Including Coupling and Motor: Less

than 90 percent of limits established in the Hydraulic Institute Standards.

F. Where specified by the individual pump sections, a complete lateral and torsional vibration analysis shall be required for each unique pump-coupling-motor rotating assembly and shall be submitted for review prior to pump fabrication.

1. Each lateral vibration analysis shall identify the lateral natural frequencies for both the pump and motor shafts. The pump shaft analysis shall include both dry and wet impeller cases. A natural frequency map shall be provided demonstrating that a lateral natural frequency does not occur within plus or minus 20 percent of the specified operating speed.

2. Each torsional vibration analysis shall include calculation of the system torsional natural frequencies and the steady-state and transient startup torsional response. An interference diagram shall be provided demonstrating a separation margin of at least plus or minus 20 percent between running speed and the expected excitation frequencies. The expected excitation frequencies for steady-state operation shall include but not be limited to, electrical line frequency, mechanical running speed (1 times shaft speed) and blade-pass frequency. The analysis shall include variable frequency drive wave-form components (where used). All motor excitation frequencies shall be provided by the motor supplier. The calculated steady-state and transient dynamic torsional shaft stresses and coupling torques shall be shown to be below allowable levels, such that the motor shaft, pump shaft, and associated drive train components are capable of an unlimited number of startups and shutdowns. The allowable shaft shear stresses (endurance limits) shall be determined in accordance with ASME B106.1M (Design of Transmission Shafting) or an equivalent method. A factor of safety of at least 2.0 shall be included in the allowable stress levels. The allowable dynamic torque in the couplings shall be compared to the coupling supplier’s allowable torques.

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2.02 MATERIALS

A. All materials shall be suitable for the intended application and shall conform to the following requirements unless otherwise specified in the pump data sheet:

1. Cast iron pump casings and bowls shall be close-grained gray cast iron, conforming to ASTM A48, Class 30, or equal.

2. Bronze pump impellers shall conform to ASTM B62 or ASTM B584. 3. Stainless steel pump shafts shall be Type 416. Miscellaneous stainless

steel parts shall be of Type 316. 4. All anchor bolts, nuts, and washers that are not buried or submerged

shall be galvanized. Buried or submerged bolts, nuts, and washers shall be Type 316 stainless steel.

2.03 PUMP COMPONENTS – GENERAL

A. Suction and discharge nozzle flanges shall conform to ANSI/ASME B16.1 and ANSI/ASME B16.5, dimensions as required.

B. Shaft Seals: The sealing system for pump shafts shall be packed stuffing box or mechanical seal as indicated in the pump data sheet supplements.

1. Mechanical Seal Requirements: a. Mechanical seals shall be of a nonfretting type requiring no

wearing sleeves for the shafts. Pump shafts shall be furnished with no reduction in size through the seal area. Mechanical seals for vertical turbine pumps shall be split type, requiring no field assembly other than assembly around the shaft and insertion into the pump or shall be balanced cartridge design in conjunction with a spool type spacer coupling as specified in the pump data sheet supplements. The arrangement shall allow removal of the seal without disturbing the pump or driver. For clear water services and solids up to 5 percent by weight, the face combination shall be hard/ soft. Otherwise, hard/hard faces shall be used. The seal design shall be such that the dynamic O-ring moves towards a clean surface as the face wears and the springs are not in the pumped fluid. The stationary seal face shall be spring loaded to provide self-alignment despite stuffing box misalignment. Mechanical seals for horizontal pumps shall be split type, requiring no field assembly other than assembly around the shaft and insertion into the pump or shall be balanced cartridge design as specified in the pump data sheet supplements.

b. Where split type mechanical seals are specified, nonshaft O-rings shall be of ball and socket type requiring no gluing. Initial seal installation at the factory shall be with nonsplit seal faces, with all

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spare seals and spare kits to have split faces. Unless otherwise specified, split mechanical seals for pumping equipment shall be capable of 400 psig service, be self-aligning, self-centering, single, Chesterton 442, or equal.

c. Where cartridge type mechanical seals are specified, the cartridge seal shall be single, balanced, flexible stator design capable of 600 psig service with O-ring secondary seals and setscrew drive with three point centering to ensure 0.003 inch of maximum perpendicularity of rotary face to the shaft. The gland shall have a flush port and be affixed to the equipment with adjustable tabs to fit irregular bolt patterns. Unless otherwise specified, the seal shall be a Chesterton 155, Crane 1B, or equal.

d. Seal Materials: 1) Metals: Type 316 stainless steel minimum for loaded parts

over 0.060-inch cross-section. For thinner parts (springs), Hastelloy-C, Alloy 20, AMS5876 Elgiloy, or other alloy that is not vulnerable to chloride stress corrosion shall be used.

2) Elastomers: Fluorocarbon Viton, preferred unless seal supplier recommends ethylene propylene for service conditions.

3) Faces: All faces shall be of homogeneous construction- surface treatments and plated faces are unacceptable. Acceptable hard faces include nickel bound tungsten carbide, self sintered silicon carbide, reaction bonded silicon carbide, or graphitized silicon carbide. Silicon carbide is preferred because of its higher pressure-velocity capability. Acceptable soft face is carbon-graphite, either Union Carbide 658RC or Purecarbon P8412.

e. Seal Environmental Controls: 1) The seal flush ports shall be piped to drain to wet well or

hub drain as shown on the Drawings with a 1/8-inch orifice plate in the line. Provide venting of the seal chamber.

2) Where specified in the pump data sheet supplements, mechanical seals shall be fitted with an Enviroseal SpiralTrac Version F, N or D, installation Type I, as recommended by A.W. Chesterton Company, Stoneham, Massachusetts. SpiralTrac shall: a) Provide fluid circulation in the seal chamber that

removes frictional heat from the mechanical seal. b) Convey particulate matter and contaminants for

removal by conveying them from the bore to the shaft by means of an integral machined spiral.

c) Remove particulate matter from the seal chamber, without seal flush water, through an integral machined exit groove.

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3) Material of construction shall be Type 316 stainless steel. The mechanical seal shall be connected to the water purge supply where indicated on the Drawings.

2. Packing Requirements: a. Where shaft packings are specified, stuffing boxes shall be tapped

to permit introduction of seal liquid and shall hold a minimum of five rows of packing and a lantern ring. Stuffing boxes shall be face attached. Stuffing box and shaft shall be suitable for field installation, without machining or other modifications, of the mechanical seal outlined above for the applicable pump and operating conditions.

b. Packing shall be three asbestos-free die-molded packing rings of braided graphite material free of PTFE, Chesterton 1400R or equal for nonpotable water services and braided PTFE material, Chesterton 1725 or equal that is FDA/ NSF acceptable for potable water services. Glands shall be two piece split construction. Where specified in the pump data sheet supplements, the impeller end of the packing shall be fitted with an Enviroseal SpiralTrac, Version P, packing protection.

c. Where the pumped fluid is clear water, pump discharge run through a 1/8-inch orifice can be used for packing lubrication. Otherwise, provide seal water flow control and monitoring as detailed on the Drawings to control external seal water flow with 5 to 30 gallon per hour flow rate, plus or minus 10 percent accuracy, Chesterton SingleFlow, or approved equal.

d. The section of each shaft or impeller hub that extends through or into the stuffing box shall be fitted with a replaceable stainless steel sleeve with a Brinell hardness of not less than 500. The sleeve shall be held to the shaft to prevent rotation and shall be gasketed to prevent leakage between the shaft and the sleeve. Minimum shaft sleeve thickness shall be 3/8 inch.

2.04 PUMP APPURTENANCES

A. Each pump shall be quipped with a 16-gauge stainless steel nameplate with 1/4-inch die-stamped equipment tag number securely mounted in a readily visible location.

B. Pumps shall be manufactured with lifting lugs for equipment weighing over 100 pounds.

C. Anchor Bolts: Galvanized sized by equipment supplier and as specified in Section 05 50 05, Anchorage of Equipment.

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2.05 FACTORY TESTING

A. The following tests shall be conducted on each indicated pump system, unless otherwise specified in the specific pump section:

1. Motors: See Section 26 20 00, Motors. 2. Pump Systems: Unless otherwise specified, all centrifugal pump

systems 100 hp and larger shall be tested at the pump factory in accordance with the Test Code for Centrifugal Pumps of the Hydraulic Institute Standards, latest edition. Unless otherwise indicated, the acceptance criteria shall be Level A with total head and pump efficiency meeting the requirements at design flow and rated rpm as specified. Testing of prototype models shall not be acceptable. The following minimum test data shall be submitted: a. Hydrostatic test data. b. A minimum of three hydraulic test readings between shutoff head

and 25 percent beyond the rated capacity, recorded on data sheets as defined by the Hydraulic Institute.

c. Pump curves showing head, flow, brake horsepower, efficiency, and NPSH required.

d. Certification that the pump horsepower demand did not exceed the rated motor horsepower beyond the 1.0 service rating at any point on the curve.

e. Pumps shall be tested at full rated speed as specified in the specific pump section.

f. Test for a continuous 3-hour period without malfunction. 3. Acceptance: In the event of failure of any pump to meet the specified

requirements, the Supplier shall make all necessary modifications, repairs, or replacements to conform to the requirements of the Contract Documents and the pump shall be re-tested until found satisfactory.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with Supplier’s printed instructions.

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

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.

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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, nonshrinking grout of the proper category. Remove wedges after grout is set and pack void with grout.

E. Connect suction and discharge piping without imposing strain to pump flanges.

F. Anchor Bolts: Accurately place using equipment templates and as specified in Section 05 50 05, Anchorage of Equipment.

G. Pipe pump drain(s) to hub drain or scupper.

3.02 SERVICES OF SUPPLIER

A. Inspection, Startup, and Field Adjustment: Where required by the individual pump sections, an authorized service representative of the Supplier shall visit the Site to witness the following and to certify in writing that the equipment and controls have been properly installed, aligned, lubricated, adjusted, and readied for operation.

1. Installation of the equipment. 2. Inspection, checking, and adjusting the equipment. 3. Startup and field testing for proper operation. 4. Performing field adjustments to ensure that the equipment installation

and operation comply with the specified requirements. 5. Provide instruction and training in the operation and maintenance of the

equipment, including step-by-step troubleshooting with all necessary test equipment. Instruction shall be specific to the models of equipment provided. All training material and a detailed outline of each lesson shall remain with the equipment at the Project Site.

B. The Supplier shall provide all necessary oil and grease required for initial operation.

3.03 PROTECTIVE COATING

A. Materials and equipment shall be coated as required by the individual pump sections and Section 09 90 00, Painting and Coating.

3.04 FIELD TESTING

A. Each pump system shall be field tested after installation to demonstrate satisfactory operation without excessive noise, vibration, cavitation, or overheating of bearings.

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B. The following field testing shall be conducted:

1. All pumping equipment shall be tested to verify proper alignment, operation as specified, and freedom from binding, scraping, vibration, shaft run-out, or other defects. Pump drive shafts shall be measured just prior to assembly to ensure correct alignment without forcing.

2. Startup, check, and operate the pump system over its entire speed range. Vibration shall not exceed 80 percent of the limits specified in HIS 9.6.4 at a minimum of three pumping conditions specified in the specific pump section.

3. Obtain concurrent readings of motor voltage, amperage, pump suction head, and pump discharge head for at least three pumping conditions at each specified rotational speed. Check each power lead to the motor for proper current balance.

4. Determine bearing temperatures by contact type thermometer. A run time of at least 30 minutes shall precede this test.

5. Electrical and instrumentation tests shall conform to the requirements of the sections under which that equipment is specified.

C. After each pumping system has satisfied the requirements, the Supplier shall certify in writing that the equipment has been satisfactorily tested and that all final adjustments have been made. Certification by the Supplier shall include the date of the field tests.

END OF SECTION

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402449.MF MEMBRANE SYSTEM WARRANTY JULY 16, 2010 46 61 33.01 - 1 ©COPYRIGHT 2010 CH2M HILL

SECTION 46 61 33.01 MEMBRANE SYSTEM WARRANTY

PART 1 GENERAL

1.01 GENERAL

A. All membrane system performance documents shall be furnished to the Owner, in a form acceptable to the Owner, simultaneously with the execution of the Agreement with Owner. Refer to the General Conditions for specific requirements.

B. The membrane system supplier (MSS) shall provide manufacturer’s warranty certificates for the membrane modules and individual equipment as specified in individual equipment specification sections, in a form acceptable to the Owner, simultaneously with the initial shop drawing submittals for the membrane system and individual equipment.

C. As stated herein, the MSS shall submit a Certificate of Extended Membrane Module Warranty to the Owner after completion of the acceptance test.

D. See also warranty information included in Section 46 61 34, Membrane Filtration Equipment.

E. In no event shall Seller be liable for any product altered outside of the Seller's factory by someone other than Seller or for a product subjected to misuse, abuse, improper installation, application, operation, maintenance or repair, alteration, accident, or negligence in use, storage, transportation or handling.

F. Seller shall not be liable for any damage or defect to equipment caused by improper use or mishandling of consumable items (i.e. process feed or cleaning chemicals) used in the operation of the treatment plant or impact.

G. Seller shall not be liable for any damage or defect to equipment caused by operation of the equipment not in accordance with seller provided Operation and Maintenance manual even if seller is not aware of the existence of these conditions. Neither shall seller be liable for repairs, alterations or replacements to or uses of the equipment, which go beyond the equipment specification.

H. Seller shall not be liable for any damage or defect to equipment caused by operation of the equipment at pressures during forward flow, air scour and reverse flow modes higher than those recommended in the Operation and Maintenance manual

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MEMBRANE SYSTEM WARRANTY 402449.MF 46 61 33.01 - 2 JULY 16, 2010 ©COPYRIGHT 2010 CH2M HILL

I. Limitation of Liabilities: Notwithstanding anything elsewhere herein contained, PALL shall not be liable for any loss or damage in excess of the purchase price of the equipment.

J. Warranty does not cover fiber damage due to foreign debris that is not native to the source water or that is larger than the fine screens.

K. Warranty is void if customer is in default of payment to Pall Corporation as defined in the terms and conditions of the contract.

L. These warranties are not the exclusive remedy for the Owner in the event of any breach of this Agreement.

1.02 MEMBRANE SYSTEM EQUIPMENT AND SOFTWARE WARRANTY

A. For a period of 1 year, commencing from the date of successful completion of the acceptance test, the MSS guarantees the following:

1. Membrane System Equipment Warranty: That all work, materials, equipment and products provided by the MSS, exclusive of the membrane modules, will be free from defects in materials and workmanship.

2. Programmable Logic Controller (PLC) Software Warranty: That MSS will make necessary changes and implement upgrades to the PLC software relating to providing solutions to all membrane system programming defects or deficiencies encountered during testing and operation of the membrane system.

B. The MSS shall make, or have made at the expense of the MSS, repairs, adjustments, replacements, or other corrective work necessary to restore or bring into full compliance with the requirements of the specifications any part of the work, materials, or equipment, which during the 1-year warranty period is found to be deficient with respect to any provision of the Specification.

C. If a defect or deficiency is of a kind which in the reasonable opinion of the Owner does not require immediate correction, and the MSS has failed to mobilize to the Site or has failed to undertake corrective work within 7 calendar days of notification from the Owner, then the Owner may make or have made such repairs, adjustments, replacements, or other corrective work and the MSS agrees to promptly pay the Owner’s invoice. Such payment shall be made within 30 days of the date shown on the Owner's invoice to the MSS.

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D. If, in the performance testing or operation of the equipment after installation, the Owner finds latent defects or finds that equipment and/or software programming fails to meet any requirements of the Specifications, the Owner shall have the right to make reasonable use of such equipment until it can be shut down for correction of defects without injury to the Owner; provided that the period of such operation pending the correction of defects shall not exceed 6 months without the written consent of the MSS.

E. All necessary software documentation will be including the O&M manuals prior to system startup. Documentations of post-startup changes to the programming will be provided as part of the final submittal.

1.03 SYSTEM PERFORMANCE WARRANTY

A. For a period of 12 months from the date of successful completion of the Initial Performance Test as described in Section 46 61 34, Membrane Filtration Equipment, the MSS shall:

1. Warrant that the membrane equipment and ancillary systems, when operated within conditions specified in the Contract Documents, will meet the performance criteria as specified in Section 46 61 34, Membrane Filtration System, and

2. Repair or replace, at no cost to the Owner, any membrane modules if membrane modules fail. Failure is defined as any of the following: a. Inability of membrane to pass integrity test as specified in

Section 46 61 34, Membrane Filtration Equipment, Article Direct Membrane Integrity Test System (MITS).

b. Inability to meet production capacity requirements under feedwater, flux, and recovery conditions specified in Section 46 61 34, Membrane Filtration Equipment, Article Performance Requirements.

c. Inability to meet cleaned membrane permeability requirements as specified in Section 46 61 34, Membrane Filtration Equipment, Article Performance Requirements.

d. Inability to meet membrane filtered water quality requirements specified in Section 46 61 34, Membrane Filtration Equipment, Article Performance Requirements.

B. Owner shall make available to MSS electronic records of historical performance for MSS review.

C. Within 7 calendar days of notification by Owner of unsatisfactory performance of the membrane system, the MSS will take the necessary actions, to maintain the performance of the membrane system in accordance with the membrane performance requirements set out in Section 46 61 34, Membrane Filtration Equipment.

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D. Where actual membrane performance falls or is anticipated to fall below the values set out in Section 46 61 34, Membrane Filtration Equipment, the MSS shall take one or more of the following corrective actions in order to maintain required membrane performance.

1. Review and optimize system operation as appropriate. 2. Repair modules. 3. Perform additional cleaning. 4. Replace modules with new modules. 5. Add modules into expansion slots. 6. Replace modules with new modules of different version, acceptable to

the Owner and Design Consultant, which offer technological advantages.

E. If the MSS is unable to modify the system through addition of membranes or other elements, and the system fails to meet the specified performance criteria in Section 46 61 34, Membrane Filtration Equipment, then the MSS shall be responsible for complete removal of the nonconforming system and subsequent installation of membrane products that are capable of meeting the specified performance conditions where the cost of such replacement does not exceed the total contract value.

1.04 EXTENDED MEMBRANE MODULE WARRANTY

A. For a period of 10 years, following the Initial Performance Test, the MSS guarantees that the membrane modules will be free from defects in materials and workmanship. Defects shall be defined as herein.

B. MSS shall provide a warranty certificate, in a form acceptable to the Owner, to secure MSS’s performance of its obligations herein. Certificate shall be submitted for Owner review and approval within 7 days of the startup of the membrane system.

C. During the first two years of the warranty period, repair and replacement shall be the sole responsibility of the MSS. MSS shall be responsible for services and all costs required to repair and/or replace defective modules, including labor, materials, tools, packaging, shipping, shipping coordination.

D. During the remaining 8-year term of the warranty, MSS shall be compensated on a pro-rata basis for replacement membrane modules supplied under the terms of this warranty to replace modules originally installed as part of the Work. The amount to be paid to MSS shall be the lower of the prices determined in accordance with the following price calculation formula:

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Replacement Module Price = (Guaranteed Membrane Module Replacement Price) X (# of months from Startup) / (120 months).

OR

Replacement Module Price = (Guaranteed Membrane Module Replacement Price) X (# of months from Delivery - 6) / (120 months).

1. Dates and warranty period determined on monthly basis. 2. Actual Guaranteed Membrane Module Replacement Price included in

bid submittal.

E. Owner shall be responsible for pulling, transferring, and returning modules to and from the preservation solution and the skid.

F. Membrane modules that serve as replacement modules under the terms of the extended membrane module warranty shall be free from defects in materials and workmanship as described herein. During the term of the extended membrane module warranty, any further replacement of the replacement modules shall be subject to the remaining membrane warranty terms as listed in Article 1.04.D.

G. The Owner shall provide the MSS with notification of any defect at least 7 calendar days in advance of its intent to remove the membrane module(s) from service to preservation. MSS shall have the option during such advance notice period to send in a technician to witness the membrane module(s) in operation prior to removal. The MSS shall repair or replace defective membrane module(s) within 14 calendar days of notification during the first year of the term. During the last 8 years of the warranty term, MSS shall ship and deliver to the site of the Work replacement membrane modules and supplies for module repairs for installation by the Owner. The 7-day advance notice shall be waived by the MSS if immediate membrane module removal and replacement is required to meet capacity requirements.

H. Defects in materials and workmanship are as defined herein:

1. Integrity Failure Defects: Membrane integrity testing shall be established to meet the design and performance criteria for each membrane module and for each membrane skid. Membrane modules shall be considered to have integrity failure defects under the following conditions: a. If a module possesses integrity breach, and cannot be repaired by

plant operations staff or manufacturer.

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b. If for a single membrane module more than 0.50 percent (one-half of one percent) of the fibers have required repair (i.e., by pinning or gluing) over the extended membrane module warranty period, then that module shall be considered to be defective and the sole remedy shall be module replacement. An individual fiber shall be defined as requiring repair if it has been determined that it is causing the system to fail the membrane integrity test as specified in the performance criteria (Section 46 61 34, Membrane Filtration Equipment).

2. Irreversible Production Loss Failure Defects: During the Initial Performance Test, the lowest observed 10-minute average clean-membrane transmembrane pressure (TMP) will be recorded. This observed value will be the benchmark to determine whether future operational TMPs (corrected for temperature to 20 degrees C) are within the specified allowance for determination of membrane module operational life. TMP will be adjusted based on the following formula:

TMP20°C = TMP Observed*e(-0.0239*(TObserved-20))

The membrane module’s operational life will be deemed to have ended and require replacement when:

a. After a CIP, the module exhibits a loss of membrane specific flux (temperature-corrected flux per unit TMP) equivalent to 50 percent or greater from the benchmark clean-membrane TMP that was recorded during the commissioning test.

b. The module TMP becomes greater than the maximum allowable TMP as stated by the MSS in its proposal over the entire membrane performance warranty period.

END OF SECTION

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402449.MF MEMBRANE FILTRATION EQUIPMENT JULY 16, 2010 46 61 34 - 1 ©COPYRIGHT 2010 CH2M HILL

SECTION 46 61 34 MEMBRANE FILTRATION EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section specifies Membrane System Supplier (MSS) requirements for hollow fiber membrane filtration system (MFS). MSS is responsible to provide a functional MFS. Requirements and materials not specified herein shall be selected by MSS for specified performance requirements and environmental conditions based on standard practice.

B. Generally, requirements include equipment supply, delivery, installation, startup testing, commissioning, training, and functional and performance testing of membrane system, support equipment, pumps, valves, instrumentation and control, and other accessories. System components shall be complete and operable, sized to treat required volume of specified water, and perform in accordance with requirements of the Contract Documents.

C. The MFS is for treatment of either raw or lime softened water at the Marco Island North Water Treatment Plant (NWTP). The MFS shall be sized to produce a maximum 6.7 mgd of net filtrate flow with the capability for future expansion to 10.0 mgd of net filtrate flow by adding two additional trains and one feed pump. The system will treat a constant feed flow rate from upstream processes and shall produce a constant filtrate flow rate to downstream as specified in this Section.

D. Work to be provided by MSS includes, as a minimum:

1. Design and fabricate MFS components and assemblies. 2. Conduct factory testing. 3. Deliver MFS equipment. 4. Provide installation assistance, quality control, quality assurance, field

inspection, and installation certification. 5. Provide onsite testing, equipment startup, and training of Owner’s

personnel. 6. Provide As-Built Drawings.

E. Work to be provided by Contractor:

1. Construct building to house MFS. 2. Install MFS with assistance of MSS. 3. Assist MSS with onsite testing and equipment startup.

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MEMBRANE FILTRATION EQUIPMENT 402449.MF 46 61 34 - 2 JULY 16, 2010 ©COPYRIGHT 2010 CH2M HILL

1.02 REFERENCES


1. American National Standards Institute (ANSI). 2. American Bearing Manufacturers’ Association (ABMA). 3. American Society of Mechanical Engineers (ASME): PTC 10,

Performance Test Code on Compressors and Exhausters. 4. American Water Works Association (AWWA):

a. ANSI/AWWA B110-09, Membrane Systems 5. ASTM International (ASTM):

a. ASTM Task Group D6908-06, Standard Practice for Integrity Testing of Water Filtration Membrane Systems.

b. D1784, Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds.

c. D1785, Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120.

d. D4189, Standard Test Method for Silt Density Index (SDI) of Water.

6. Hydraulic Institute Standards (HIS). 7. National Electrical Manufacturers’ Association (NEMA): MG 1, Motors

and Generators. 8. NSF International (NSF): 61, Drinking Water System Components -

Health Effects. 9. Occupational Safety and Health Act (OSHA). 10. United States Environmental Protection Agency (EPA):

a. Long Term 2 Enhanced Surface Water Treatment Rule, as published in U.S. Federal Register (January 5, 2006).

b. Membrane Filtration Guidance Manual (November 2005).

1.03 DEFINITIONS

A. Refer to ANSI/AWWA B110-9 Membrane Systems Standard for general definitions. Definitions here expand on the Membrane Systems Standard and take precedence, where applicable:

B. Basis of Design: Synonymous with “Design Conditions” as defined herein.

C. Chemical Wash (CW) Train Interval:

1. Period of operation between CW events for a train of MFS. 2. Where CWs are conducted sequentially using two different chemical

solutions e.g., citric acid followed by hypochlorite, the sequential CWs shall be considered as one CW event.

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D. Clean In Place (CIP) Train Interval:

1. Period of operation between CIP events for a train of MFS. 2. Where CIPs are conducted sequentially using two different chemical

solutions e.g., citric acid followed by hypochlorite, sequential CIPs shall be considered as one CIP event.

E. Cleaned Membrane Permeability: Permeability, temperature-corrected to 20 degrees Celsius, of a membrane train following return to service after a CIP and calculated as first-hour average permeability.

F. Feedwater: raw water or softened water.

G. Filtrate Production Capacity: Net filtrate flow available for further treatment over a 24-hour period of normal operation as defined herein.

H. Functional Test: Operation of MFS valves, controls, and other devices to ensure they are functional and ready for performance testing.

I. Initial Performance Test: Test, with MSS’s assistance, to demonstrate installed system meets performance requirements specified herein. 30-day operational period of MFS starting after successful completion of Functional Test.

J. Instantaneous Flux:

1. Filtrate flow rate of a membrane train measured at a given time train is in production, divided by active membrane surface area (feed side) of membrane train. May be calculated as Net Flux divided by percent on-line service factor (%SF), expressed in gallons per day per square foot (GFD)

2. For example, system with net flux rate of 40 GFD and a %SF of 96.7 percent has a calculated instantaneous flux of 41.4 GFD (40 GFD÷96.7%=41.4 GFD).

K. Membrane Module Warranty Period: Length of Guaranteed Membrane Life (GML) as provided in Purchase Order. Membrane Module Warranty Period shall begin after successful completion of Initial Performance Test.

L. MFS Recovery:

1. Net volume of membrane-filtered water available for further treatment divided by total volume of feed water entering membrane train(s) from prefilter system over a 24-hour period, expressed as a percentage. MFS Recovery is equal to 1 minus combined MFS waste liquid volume (considering backwash, tank drainage, etc.) divided by membrane feed water volume, then multiplied by 100 to convert to a percentage.

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2. For example, system with 0.5 MLD waste liquid volume and 10 MLD feed water has a feed water recovery of 95 percent [[1 - (0.5/10)] x 100 = 95%].

3. Synonymous with Membrane System Recovery, Membrane Recovery and Feedwater Recovery.

M. Membrane Train:

1. Membrane unit that has single feed water connection point, operates in parallel with other membrane units, and is independently controlled, backwashed, and cleaned. A train shall be fully isolatable from other trains.

2. Synonymous with Train.

N. Net Flux:

1. The 24-hour average filtrate production available for further treatment in gallons per day divided by active membrane surface area (feed water side) in square feet. Units of net flux are gallons per square feet per day (GFD). Net Flux is equal to Instantaneous Flux multiplied by percent on-line service factor (%SF).

2. For example, system with Instantaneous Flux of 41.4 GFD and a %SF of 96.7 percent has a calculated net flux of 40 GFD (41.4 GFD x 96.7% = 40 GFD).

O. Normal Operating Mode:

1. Encompasses operating modes routinely used by MFS, including forward flow, normal backwash, chemical wash, and other operations proposed by MSS on a daily basis to meet performance requirements herein. Normal operation also encompasses membrane integrity testing (MIT) as required to meet performance requirements herein.

2. Also defined as follows: a. N Condition: All trains in operation. b. N-“x” Condition: All but “x” trains in operation, with non-

operating train(s) not to be used for meeting filtrate production requirements when other train(s) are out of service for backwash, chemical wash or MIT; “x” is defined as a whole integer ranging from 1 to 4.

c. Where MFS is required to meet Filtrate Production Capacity in a “N-1” condition (all but one train in service), “N-1” does not account for additional trains being out of service

P. On-Line Service Factor (%SF): Average percent of time per day membrane train is producing treated water (forward flow) other than for use in cleaning operations as part of Normal Operating Mode.

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Q. Permeability: Instantaneous Flux rate (in GFD) divided by transmembrane pressure (in psi). Units of permeability are GFD per psi.

R. Post-CIP Fouling Rate: Percent decrease in temperature-corrected permeability over 5 days of run time following a clean-in-place; expressed in units of GFD per psi per day at 20 degrees C.

S. Pre-filter (Strainer or Screen) System Recovery: Total volume of pre-filtered water delivered to MFS divided by total volume of feed water entering prefilter system over a 24-hour period; expressed as a percentage.

T. Proposed Guaranteed Performance Criteria: MSS’s guaranteed values for the following parameters at the measured feed water quality, with feed water quality and guaranteed values taken as a 24-hour average (midnight to midnight):

1. Filtrate production capacity. 2. Maximum instantaneous flux. 3. Minimum system recovery. 4. Minimum train CW interval. 5. Minimum train CIP interval. 6. Minimum filtrate quality. 7. Minimum train integrity.

U. Service Cycle: Period of time between startup of membrane process following a CIP event and initiation of subsequent CIP event.

V. Temperature-Corrected Flux or Flux at 20 degrees C: Measured Net Flux or Instantaneous Flux multiplied by a temperature correction factor (TCF) warranted by MSS, expressed in the following form:

( )T20T20 TCF x JJ −=

Where: J20 = Flux at 20 degrees C

JT = Flux at measured water temperature T = Measured water temperature in degrees C

W. Temperature-Corrected Permeability or Permeability at 20 degrees C: Temperature-corrected Instantaneous Flux rate (in GFD) divided by measured transmembrane pressure (in psi). Units of temperature-corrected permeability are GFD/psi.

X. Terminal TMP:

1. Highest transmembrane pressure under which membrane train would typically be operated, expressed in units of pounds per square inch (psi). Used as criteria for indicating when membrane train requires CIP.

2. Synonymous with maximum TMP.

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1.04 SYSTEM REQUIREMENTS

A. See ANSI/AWWA Membrane Systems Standard Sec. 4.2.

1.05 PERFORMANCE REQUIREMENTS

A. Guaranteed Performance Criteria:

1. MSS’s proposed guaranteed performance criteria for the following parameters shall be met on a daily basis calculated as an arithmetic mean of values measured over a 24-hour period (midnight to midnight). a. Filtrate production capacity. b. Steady feed flow. c. Steady filtrate flow. d. Maximum net flux. e. Maximum instantaneous flux. f. Minimum net system recovery. g. Minimum train CW interval. h. Minimum train CIP interval. i. Minimum train filtrate quality. j. Minimum train integrity.

2. If MFS feed water turbidity, TSS, or TOC values exceed respective maximums shown in Table 46 61 34-2, one or more of the guaranteed performance criteria may be subject to modification with consent of Engineer and Owner.

3. Filtrate Production Capacity: Over a 24-hour period shall be as follows: a. Met with MFS operating in an “N” condition unless otherwise

specified, where “N” is defined under Normal Operating Mode in Article Definitions.

b. Met with at the specified reduced filtrate flow rate with the MFS operating in an “N-1” condition unless otherwise specified, where “N-1” is defined under Normal Operating Mode in Article Definitions.

c. Met over entire range of MFS feed water quality conditions. d. Met while meeting other requirements specified herein including

membrane system recovery, CW/CIP frequency, flux, permeability, and filtrate quality.

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B. Performance limits:

1. Performance criteria limits are presented in Table 46 61 34-1. Table 46 61 34-1

MFS Performance Requirements Criterion Units Value Notes

Filtrate production capacity

mgd 6.7 During Normal operation

mgd 5.0 During N-1 operation mgd 10.0 Future expansion capacity (N+2) Steady feed flow Size system to manage flow within the

equalization capacity of the feed tank Steady filtrate flow percent +/- 5 Maximum change over 5 minutes Membrane system flux

GFD 65 Maximum 24-hour net average

GFD 90 Maximum instantaneous Design temperature Celsius

20

Design for filtrate production capacity

Membrane train CW interval

Hypochlorite hours 24 Minimum 36 Average over 30-day period

Citric acid hours 72 Minimum 168 Average over 30-day period Membrane train CIP Interval

days 30 Minimum

45 Average over 180-day period Membrane train filtrate quality

NTU <0.1 >95% of time

NTU <0.3 100% of the time Or in accordance with USEPA MFGM Membrane train integrity

LRV 4.0 95% of the time

3.5 100% of the time Trans-membrane pressure

PSI Less than value stated by MSS

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Chemical cleaning performance

percent 80 Of initial permeability during years 1-2

percent 70 Of initial permeability during years 3-5 percent 50 Of initial permeability during years 6-10

C. Membrane Train Integrity:

1. MFS shall include an automated direct integrity monitoring system (DIMS) for each membrane train meeting requirements of U.S. EPA Long Term 2 Enhanced Surface Water Treatment Rule, as published in the U.S. Federal Register (January 5, 2006) and in accordance with U.S. EPA Membrane Filtration Guidance Manual (November 2005).

2. Integrity of each membrane train shall be maintained at a log removal value (LRV) of 3.5 or greater at all times based on measurements from the DIMS and as described in Article Direct Integrity Monitoring System.

3. DIMS shall be operated in a manner to detect integrity breach of 3 um or less.

D. Chemical Cleaning of Membranes:

1. Perform through CWs and CIPs. 2. Restoration of Membrane Permeability: CIP operation shall be

sufficient such that, following return of each membrane train to service, cleaned membrane permeability shall be greater than or equal to the following values following completion of Initial Performance Test: a. 80 percent of initial permeability (corrected to 20 degrees C)

during years one and two of operation. b. 70 percent of initial permeability (corrected to 20 degrees C)

during years three through five of operation. c. 50 percent of initial permeability (corrected to 20 degrees C)

during years six through ten. 3. If cleaned membrane permeability is less than specified minimum, or if

post-CIP fouling rate does not meet specified tolerance, two additional CIPs will be allowed to attain specified requirements. If, after the two additional CIPs, membranes fail to conform with cleaned membrane permeability or post-CIP fouling rate requirements, MFS will replace one or more membrane modules to achieve required 20 degree C permeability during membrane guarantee and warranty period at no cost to Owner.

1.06 MSS SUBMITTALS

A. Bid Submittal:

1. Provide electronic copy in PDF format of items described herein with Bid Proposal.

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2. Exceptions: Identify exceptions to Specification(s). 3. See AWWA Standard B110 Section 4.3.1 for additional requirements 4. MSS standard terms and conditions with supplemental terms per

agreement with the City 5. Equipment list that indicates items included in the MSS scope of supply 6. Proposed system description including sizing, functional description and

operating conditions that indicate compliance with the Specifications 7. Life Cycle cost factors including anticipated first-year annual average

power and chemical consumption, as well as guaranteed membrane replacement price.

8. Per Diem rate for additional on-site service days in addition to those included in this Specification.

9. Warranty: a. Information on membrane warranty, specific to this Project and as

specified. b. Confirm number of years of non-pro-rata period of membrane

warranty. c. Indicate number of years for pro-rata membrane warranty.

10. Air system requirements 11. Chemical feed system requirements

B. First Submittal:

1. MSS shall provide a CD with electronic versions in PDF format, as well as six hard copy sets of the following Shop Drawing items.

2. Updated Bid Submittal items as required. 3. Process & Instrumentation Drawings. 4. Electrical one-line diagram. 5. Mechanical layout and plan drawings of proposed skid equipment.

C. Shop Drawings:

1. MSS shall provide a CD with electronic versions in PDF format, as well as six hard copy sets.

2. See AWWA Standard B110 Section 4.3.2 for additional requirements. 3. System Components:

a. Mechanical: 1) Cut sheets and data sheets including, but not limited to,

manufacturer, model, weight, horsepower, size, options, power requirements, manufacturer’s catalog information, descriptive literature, specifications, identification of materials of construction, range (if applicable), and pump curve (if applicable) on the following mechanical components: a) Feed pumps. b) Feed strainers.

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c) Backwash pumps. d) CIP recirculation pumps. e) Motors. f) Valves. g) Other equipment.

2) Provide expected outside utility requirements such as high pressure air, water, power, and drain for each component.

3) Define hoisting equipment, if any. b. Instrumentation and Control:

1) Cut sheets and data sheets including, but not limited to, manufacturer, model, power requirements, manufacturer’s catalog information, descriptive literature, specifications, identification of materials of construction, range on instruments.

2) List and provide catalog information for major process PLC control and communication.

3) Describe instrumentation, software, hardware, control features, remote system monitoring, data storage, and alarms.

c. Electrical: 1) Provide total connected electrical load in kW, kVA, and

amperes for MFS including ancillary equipment furnished. 2) List three-phase electrical components and horsepower

rating or load in amperes and voltage. 3) List components that will run off power supply other than

480 volts, three-phase. 4) Provide wiring diagrams for equipment and interconnection

wiring diagrams. 5) Provide calculation of the average power consumption.

d. Spare Parts: 1) List of manufacturer’s “standard” spare parts, including

items listed in Article Extra Materials. 2) Recommendations for spare parts and materials for first

12 months of system operation. 3) Provide price list for standard, recommended, and specified

spare parts. 4. Narrative Operation Descriptions:

a. Describe MFS and operation control procedures for an individual train and entire system, including operation of backwash water recycle system.

b. Describe procedures for access, inspection, and removal, repair, and replacement of membrane modules.

c. Describe startup, and normal operation procedures as well as methods for maintaining and recovering membrane system permeability (backwashing, CWs, CIPs as applicable).

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d. Shutdown/Storage/Startup: 1) Describe procedures for complete shutdown, storage of

membranes and related equipment, and startup. 2) Detail process equipment necessary to accomplish long term

shut down of the plant. 3) Detail chemical(s) required and estimated annual use for

storage. e. Detail, if necessary, minimum membrane flow requirements to

preserve membrane integrity during shut down. 5. For software, provide narrative description of control system, logic

diagrams, summary of control functions, summary of monitoring functions, description of alarms, and other information to describe the control system. a. Final OIT Graphics and I/O Lists:

1) Coordinated and conformed. 2) Include tags to/from PCS and plant-wide SCADA. 3) Final OIT graphics shall illustrate functionality required to

operate MFS. 6. MSS shall submit factory test procedures 7. Refer to Section 40 99 90, Package Control System for additional

submittal requirements. 8. Refer to Section 26 20 00, Low Voltage AC Induction Motors for

additional submittal requirements.

D. Pre-Startup Submittal:

1. See ANSI/AWWA Standard Spec Section 4.3.3. 2. Testing related submittals. 3. MSS shall provide eight sets and one PDF file formatted CD-ROM disc

of Operation and Maintenance Data (O&M): a. In accordance with Section 01 78 23, Operation and Maintenance

Data. b. Submit preliminary O&M data 30 days prior to equipment

delivery and subsequent functional and performance testing.

E. Post-Startup Submittal: MSS shall provide six copies, unless otherwise noted, of the following items prior to final completion:

1. Executed warranties. 2. Manufacturer’s Certificate of Proper Installation, in accordance with

Section 01 43 33, Manufacturers’ Field Services. 3. Three copies of data summary from testing and startup period in

electronic format on CD ROMs. 4. List of original equipment by model and part number (detailed bill of

materials). List manufacturer names, addresses, and phone numbers.

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5. Three copies of the Final O&M Manual in electronic MS Word and PDF format on CD ROMs incorporating review comments from draft manual and lessons learned from completion of start-up and testing.

6. Three copies of the Final O&M Manual in hard copy format incorporating review comments from draft manual and lessons learned from completion of start-up and testing.

7. Three copies of final HMI screen programs with the MSS standard comments and documentation in electronic format. Provide on CD-ROMs.

8. Three copies of each final PLC program with the MSS standard annotations, comments and documentation in electronic format. Provide on CD-ROMs.

9. One copy of the PLC software identical to software used by MSS to develop PLC(s) programs.

1.07 QUALITY ASSURANCE

A. MSS’s Field Representative Qualifications: Individual who has previously provided onsite services for installation, testing, and startup of MSS’s identical system at a minimum of one treatment facility plant of similar size but no less than 2 mgd design capacity.

1.08 SCHEDULING

A. Bid Submittal: With final proposal before contract execution.

B. First Submittal: Within 35 days from NTP.

C. First Resubmittal (if required): Within 14 days of receiving comments.

D. Shop Drawings: Within 45 days from approved First Submittal.

E. Shop Drawings Resubmittal (if required): Within 14 days of receiving comments.

F. Pre-Startup Submittal: Greater than 30 days before Equipment Delivery.

G. Equipment Delivery: Within 21 weeks from approved Shop Drawings.

H. Post-Startup Submittal: Within 30 days of successful completion of initial performance test.

1.09 GUARANTEE AND WARRANTY

A. MSS shall provide a guarantee and warranty for MFS in accordance with requirements of Section 46 61 33.01, Microfiltration and Ultrafiltration Membrane Equipment Warranty.

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PART 2 PRODUCTS

2.01 GENERAL

A. Products to be furnished under this section are as follows:

1. Strainers. 2. Membrane filtration trains, including modules. 3. Membrane feed pumps, including appurtenances. 4. Backwash system, including filtrate equalization/backwash supply tanks

and pumps, as applicable. 5. Cleaning system for conducting CW and CIP, including tanks pumps

and valves, as applicable. 6. Membrane integrity test system. 7. Intra-system piping, including piping on racks and skids. 8. Manual and actuated valves outside of skids as shown on P&IDs. 9. Electrical. 10. Motors in accordance with Section 26 20 00, Low Voltage AC

Induction Motors. 11. Instrumentation and controls in accordance with Section 40 99 90,

Package Control Systems. 12. Spare equipment, special tools, and chemicals.

B. Items to be furnished shall be MSS’s standard unless otherwise indicated. Items shall be new and unused and shall be MSS’s most current product line at time of product submittal. Provide and list separately a deduct for use of standard equipment in lieu of specified equipment manufacturers.

C. Equipment shall comply with OSHA standards.

D. Terminal point connections shall be ANSI standard flanges.

2.02 MFS SUPPLIER

A. Materials, equipment, and accessories specified in this section shall be products of:

1. GE Water & Process Technologies. 2. PALL Corporation.

2.03 SERVICE CONDITIONS

A. Owner will provide raw or softened water to MFS via gravity pipeline into a feed tank. Contractor shall provide the Work necessary for delivery of raw or softened water from the feed tank to MFS’s connection point.

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B. Upstream water treatment process includes one of the following unit processes:

1. No treatment. 2. In-line alum coagulation. 3. Lime softening/clarification.

C. MSS shall provide coordination and integration of processes and process control for interfaces to immediate upstream and downstream processes.

1. Provide process control logic for interfaces to upstream and downstream processes.

2. This effort shall include, but not be limited to, process control logic, coordination, testing, and startup of items associated with interface to upstream and downstream processes.

3. Process control requirements shall be included in final process control narrative.

D. Equipment will be installed in an Owner-provided building, which will be constructed by Contractor. Temperature within building will range from 50 F to 104 F at minimum and maximum conditions, respectively.

E. Backwash wastewater will be discharged to a dedicated line for equalization, treatment and recycle to treatment plant.

F. Filtrate required for backwash will be supplied from backwash tank, included in the MSS scope of supply. Filtrate produced for downstream use shall be discharged at a minimum pressure of 14 psig.

G. Filtrate required for CW and CIP will be supplied from a plant water system, not included in the MFS scope.

H. Feed Water Quality:

1. Water quality data for raw or softened water, heretofore referred to as MFS feed water, is presented in Table 46 61 34-2.

2. Represents expected quality for MFS feed water. 3. Performance guarantees and system performance criteria listed herein

shall be achieved by MFS when operating on feed water having a quality that falls within ranges for each parameter listed in Table 46 61 34-2.

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Table 46 61 34-2

MFS Feed Water Quality

WQ Parameter Units Maximum Minimum Average

pH Std. Units 8.8 8.4 8.6 Alkalinity mg/L as

CaCO3 40 25 35 Total Hardness mg/L as

CaCO3 120 100 110 Turbidity NTU 15.0 1.0 2.5 TDS mg/L 522 223 442 Color PCU 45 5 7 Chloride mg/L 160 81 122 TOC mg/L 18.0 6.0 8.4 Temperature ºF 84 68 77.1 Iron mg/L <0.3 <0.3 <0.3 Manganese mg/L <0.05 <0.05 <0.05

2.04 PROCESS CONTROL

A. Membrane system will receive and treat feed water and pass filtrate to the downstream process. MFS shall continuously process feed water as required by Filtrate Production Capacity requirements. MSS shall provide automated features with system design, PCS, and equipment to automatically operate the membrane system 24 hours per day accounting for individual membrane trains being out of service for backwashing, MIT, or CW.

B. Steady Feed Flow:

1. Flow to MFS system will be steady throughout the day with changes occurring less than 4 times per day. MSS shall provide a process control strategy that responds automatically to changing feed flows throughout the day. MSS process control strategy shall also be coordinated with upstream process and provide a constant flow to downstream processes.

2. Membrane process control strategy shall accommodate incoming variable flow. Process control strategy shall adjust operation of MFS to maintain operating level in the feed water tank. Process control strategy shall not depend on a constant MFS feed flow or being able to bypass flow around MFS to be able to maintain a constant flow through membrane systems.

3. Membrane system performance requirements shall be met with constant membrane feed flow and constant membrane filtrate flow (downstream of the filtrate equalization/backwash tank) process control strategy.

4. The membrane system must be capable of treating steady feed flow at the required rate when one train is removed for service to conduct MIT or CW. Such operation shall not be considered an N-1 or N-2 condition.

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5. The membrane system shall be programmed so that only one train is out of service at any given time for backwash, CW or MIT thus maintaining the N condition.

C. Steady Filtrate Flow:

1. Steady over a 24-hour period as specified herein. 2. To provide smooth, uninterrupted flow to downstream systems, when a

membrane train enters backwash, filtrate production shall be maintained by ramping up filtrate production of trains in service.

3. The system shall be sized to ensure constant filtrate production at the design flow rate when one train is removed from service to conduct MIT or CW. Such operation shall not be considered an N-1condition.

4. The membrane system shall be programmed so that only one train is out of service at any given time for backwash, CW or MIT thus maintaining the N condition.

2.05 CONNECTION POINTS

A. Terminal point connections to MFS shall be ANSI standard flanges.

B. Provide single connection points at MFS for the following:

1. Feed water. 2. Filtrate. 3. CW/CIP waste. 4. Sodium Hypochlorite. 5. Citric acid. 6. Sodium hydroxide. 7. Other chemical as specified by MSS.

C. Provide single connection points for each membrane train for the following:

1. Feed. 2. Filtrate. 3. Backwash supply. 4. Backwash waste. 5. Cleaning solution feed. 6. Cleaning solution return. 7. High pressure compressed air. 8. Low pressure compressed air.

D. Provide connection points at each train for:

1. MFS PLC remote I/O network. 2. Electrical Power: Single connection point.

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E. Piping and electrical connection points to strainers, backwash pumps, and feed pumps shall be as required for each component. Provide a single connection point at each motor for electrical power and motor protective devices.

F. Connections for the CIP system as follows:

1. Acid tank makeup water fill, chemical fill, overflow, CIP return, and drain.

2. Caustic tank makeup water fill, chemical fill, overflow, CIP return, and drain.

3. CIP skid electrical (single point connection), control signal terminal block, piping inlet, piping outlet and piping drain

4. As needed for tank heaters and tank instrumentation

G. Connections for the drain pump skid:

1. Electrical (single point connection). 2. Control signal terminal block. 3. Piping inlet. 4. Piping outlet.

H. Air compressors, silencer, filters, dryer and other accessories for a fully functional system shall have one connection point for interconnecting piping between air compressor system and membrane trains and one connection point for electrical power.

2.06 MEMBRANE SYSTEM EQUIPMENT

A. Chemical Metering Pumps: The MFS will control the operation of these pumps. But, chemical feed equipment is excluded from the MFS scope.

B. Prefilter (Strainer) System: MFS shall be suitable for operation with a prefilter system fitted with a (300-micron) sized screen. Prefilter system shall be supplied by MSS.

C. Membrane Trains and Modules:

1. Each membrane train shall be designed for installation of additional modules equal to or greater than 10 percent of installed number of modules (empty module spaces). Where MFS instantaneous flux rate must be reduced to meet performance requirements, MSS may install, at no additional cost to Owner, additional modules in empty module spaces.

2. Membranes: Meet the following requirements: a. Comprised of hollow fibers. b. Operate in an outside-in flow configuration.

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c. Have a nominal pore size equal to 0.1 um or less. d. Resistant to free chlorine and other oxidants.

3. Membrane module rack (skid) shall be manufactured of powder-coated steel. Skid shall include bolt holes for mounting on concrete pad.

4. Isolation and Removal of Membrane Modules: Provide valves or other means of isolating each individual module from remainder of system, enabling train to produce water with one or more modules out of service.

D. Membrane Feed Pumping:

1. Approximate pump discharge elevation is 39.75 feet. Approximate pipe length of membrane permeate piping to downstream process is 300 feet. MSS shall confirm permeate/feed pump requirements with Engineer. Floor elevation where pumps are to be installed is approximately 9.3 feet. For conservative pump sizing, assume that only a flooded suction and minimum Net Positive Suction Head (NPSH) requirements will be provided.

2. The Membrane System Feed Pumps shall meet all requirements in Section 44 42 56, Pumps - General, but modified as follows: a. Testing shall be performed on one pump at a minimum. b. If test on initial pump do not meet requirements, all remaining

pumps must be tested at supplier’s cost. c. On-site vibration testing for feed pumps only.

3. Manufacturer: Peerless.

E. Backwash System:

1. Provide backwash pumps, agitation air blowers, isolation and check valves, meters and controls, and other components to provide automated backwash system, as applicable.

2. Pumps: Provide a minimum of one duty backwash pump and one standby pump.

3. Backwash and supply water supplied from combined permeate pipe header provided by Contractor.

4. Initiation and functions shall be automatically controlled by MFS PLC. Backwash shall be automatically initiated based on time, TMP, or filtrate (permeate) volume. System shall also allow operator to initiate a backwash and control each piece of equipment and valves manually. MFS PLC shall record time and duration of each backwash.

5. Refer to Section 44 42 56, Pumps – General, for additional requirements.

6. Manufacturer: Peerless.

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F. Direct Integrity Monitoring System (DIMS):

1. Include DIMS for each membrane train meeting requirements of the U.S. EPA Long Term 2 Enhanced Surface Water Treatment Rule, as published in the U.S. Federal Register (January 5, 2006) and in accordance with the U.S. EPA Membrane Filtration Guidance Manual (November 2005).

2. Features: a. Operate automatically, controlled by MFS PLC. b. Operator-adjustable frequency of testing with a range of 12 hours

and 168 hours. c. Automatically alarm a failure.

3. Frequency: a. Once every 24 hours. b. If a 30-minute running average turbidity for a membrane train is

above 150 mNTU (0.15 NTU), perform direct integrity test on train.

4. LRV for each train shall be calculated in accordance with requirements of the U.S. EPA Long Term 2 Enhanced Surface Water Treatment Rule, as published in the US Federal Register (January 5, 2006) and in accordance with the U.S. EPA Membrane Filtration Guidance Manual (November 2005). a. MSS shall submit detailed methodology that clearly shows how

train LRV is calculated based on DIMS results and train/system configuration.

5. Conduct direct integrity testing using pressure applied to filtrate side of membrane in accordance with ASTM Task Group D19.08.02: REVISION J.

6. Train integrity failure shall be defined as air pressure decay rate that equates to a LRV of less than 3.5 for membrane train.

G. Membrane Cleaning and Other Associated Equipment:

1. Provide pumps, tanks, mixing devices, actuated valves, chemical injection assemblies, controls, and other system components to provide for proper operation and functioning of the CW and CIP systems.

2. All tanks shall have its discharge invert located flush with the bottom of the tank.

3. CIP system shall be designed to remove solids and dissolved compounds that have accumulated in membrane modules, including on membrane surface and within membrane pores, such that clean water permeability of membrane is consistently restored to a minimum value as specified in Article, Performance Requirements.

4. Cleaning system shall be designed for automatic operation once a cleaning cycle has been initiated by operator.

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5. Spent cleaning solutions shall be discharged to the existing reclaimed water wet well to be connected by the Contractor. a. MSS shall provide equipment and systems discharge waste to wet

well. 6. CIP and CW Control and Monitoring:

a. Provide controls for chemical systems through MFS PLC(s). 1) MFS PLC(s) shall record time between chemical cleanings

and send alarm when next chemical cleaning is needed based on operator-entered time interval or an increase in TMP.

2) Controls shall automatically shut down membrane train if pH or chlorine residual levels are outside set points.

3) Control system shall record time between CWs and CIPs.

H. Piping:

1. General: a. Install true union fittings where future disconnection may be

required. b. Piping color shall be selected by Owner.

2. MSS shall be responsible for: a. Piping within each membrane train and within train’s

corresponding pipe rack: 1) Feed. 2) Filtrate. 3) Backwash supply. 4) Backwash waste (normal and CW). 5) CIP feed and return. 6) High and low pressure air.

b. Actuated valves, and in-line instruments and controls for ancillary systems, including: 1) Pre-strainer system. 2) Chemical feed systems for CIP and CW. 3) Low-pressure air system. 4) High-pressure air system. 5) Backwash system 6) Membrane integrity test system. 7) Air distribution to on-rack valves and off-rack valves

specified in this Specification. c. Automated isolation system on filtrate and CIP lines to prevent

contamination of filtrate with chemical cleaning solution. Preference is given for a block-and-bleed system that establishes an air gap.

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3. Contractor shall provide interconnecting process piping between trains’ pipe racks for MFS, and between membrane trains/pipe racks and ancillary equipment including backwash pumps, CIP system, low pressure air system, and high pressure air system.

4. Liquid Service Piping: a. Piping for liquid service shall be Type 316L or higher-grade

stainless steel, or HDPE. Piping shall meet all applicable ASTM and AWWA standards.

b. All Type 316L stainless steel piping shall be pickled and passivated (including factory and field welds) and be provided with low point drains to empty all piping when not in use for extended periods of time.

c. Designed to limit maximum flow velocities to 8 feet per second (fps) at maximum flow. 1) If unable to meet 8 feet per second flow criteria, indicate

and describe locations where velocities are greater than 8 feet per second.

2) Velocities greater than 8 feet per second shall be considered as part of the nonprice factor evaluation.

5. High-Pressure Air Lines: a. Type 316 stainless steel pipe. b. PVC is not acceptable for air pipelines.

6. Low-Pressure Air Lines: a. Designed to limit maximum flow velocities to 40 feet per second

at maximum flow. b. If unable to meet 40 feet per second flow criteria, indicate and

describe locations where velocities are greater than 40 feet per second.

c. Velocities greater than 40 feet per second shall be considered as part of the nonprice factor evaluation.

7. Chemical Solution Piping: Schedule 80 PVC, conforming to Type I, Grade I, ASTM D1784 and ASTM D1785.

I. Manual and Actuated Valves:

1. MSS shall provide check valves, control valves, and isolation valves except for feed pump inlet/outlet, strainer inlet/outlet, chemical feed systems and backwash pump inlet/outlet valves required for a completely functional system (shipped loose and properly labeled, if not provided as part of each membrane train or pipe rack): a. Gate Valves:

1) Conform to AWWA C500. 2) Iron body, bronze mounted, flanged ends, double disc gate,

nonrising bronze stem, rated 150-pound WOG. 3) AWWA C550 epoxy lining.

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b. Ball Valves, (PVC) 2-Inch and Smaller: Nibco True-Bloc, ASAHI America Duo-Bloc, or equal.

c. Equipment Air Ball Valves: Milwaukee BA100ELD, Apollo 75-100-41, or equal.

d. Butterfly Valves: 1) Conform to AWWA C504. 2) Class 150B, flanged end, short body type, cast iron body,

cast or ductile iron disc with Type 316 stainless steel shaft, EPDM seat and stainless steel seating surface.

3) AWWA C550 epoxy lining. 4) Manufacturers and Products:

a) Bray; Series 30. b) Valves located on a manufacturer’s valve rack may be

“equals” e. Solenoid Valves: MSS’s standard, 120 volts, 60 HZ ac. f. Check Valves:

1) Lever-weighted swing check, cast-iron body, bronze body seat, bronze mounted cast-iron clapper with rubber seat, stainless steel hinge shaft.

2) Manufacturers: Kennedy or Mueller Co.; No. A-2600 Series.

2. Pneumatic Actuators: a. Guaranteed for 1,000,000 cycles with less than 5 percent failure. b. Include air sets, exhaust mufflers, speed controls, pilot solenoids,

and accessories. c. Manufacturer:

1) Pneumatic Actuator: Keystone 79U. 2) Pilot Solenoid Valves: Asco Red Hat or C.A. Norgren Co.

3. Sample Valves: Provide 1/2-inch stainless steel ball valve sample taps, with female thread on outlet, at the following locations: a. Strainer influent. b. MFS feed (strainer effluent). c. Filtrate (from each train). d. Backwash supply (following CW chemical injection) e. Backwash waste (normal and CW). f. CIP solution (at CIP pump discharge).

J. Instrumentation and Controls:

1. General: a. Control functions contained and described herein are intended to

provide proposed minimum performance requirements. They do not necessarily identify each and every control function, connection, communications, or equipment to achieve the requirements. Additional specificity and details shall be coordinated at time of submittals

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b. Provide control system components and testing in accordance with Section 40 99 90, Package Control Systems.

c. Panel Numbers: Manufacturer’s standard. d. Control panels shall be freestanding NEMA 4X Type 304

stainless steel. Power supply to each panel will be one 120V ac, 60-Hz, single-phase circuit.

e. Provide application software for digital, programmable components of membrane systems. Provide Owner with a copy of the professional version of Rockwell Automation RSLogix 5000 PLC programming software with Ladder Logic, Structured Text, and Function Block programming packages and any required software licenses

f. Provide standard software and software licenses. 2. Controls:

a. Controls for components of membrane system shall be provided by a dedicated non-redundant programmable logic controller (PLC) mounted in a main membrane control panel. 1) Provide dedicated remote input/output (I/O) rack for each

membrane mounted at each membrane train. b. PLC shall provide control and monitoring functions as required

for operation, monitoring, and control of membrane systems including but not limited to timing, interlocks, start-up sequencing, normal start-up/ shutdown sequences, emergency shutdown, operator interface, permissives, and process control interfaces to/from upstream processes and downstream processes. 1) Programming Standards:

a) Manufacturer’s Standard. b) Programming shall be customized for this Project as

required. c) Tags shall be accessible by plant SCADA system for

monitoring. 2) PLC I/O Signals: Refer to P&ID Drawings. 3) Field alarm instruments and contacts shall be wired for

failsafe operations where an open circuit will alarm. c. PLC communications and faults shall be monitored.

1) Indicating Lights: a) Colors in accordance with Owner I&C Design

Standards. b) Equipment tag numbering will Manufacturer’s

standard. d. Uninterruptible power supply (UPS) backup power for MSS

control panels (main control panel and remote I/O panels) will be supplied by the MSS. 1) Provide UPS in the main control panel and size to provide

120V AC power to all control devices in the control panel and on membrane trains including but not limited to the

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PLC, Remote I/O, OIU, Ethernet Switches, 24V dc power supplies, network equipment, and other electronic devices. The batteries for the UPS shall be sized to power all connected equipment to provide a safe shutdown of the membrane filtration system.

2) PLC I/O, control circuits, instrument components, and all other devices required to provide safe shutdown of membrane control system shall be included on UPS power.

e. Communications Network: Provide Ethernet TCP/IP 10/100 mbps network communications module to support communications between PLC and Owner’s plant control system network. Provide Ethernet TCP/IP Fast Ethernet connections between remote I/O panels and main MFS control panel as shown on the Drawings. 1) MSS communication protocol shall be Ethernet/IP and the

MSS shall provide coordination of membrane system to plant system communications.

2) Provide all I/O modules as required to support the membrane system plus 20 percent spare. All I/O shall be wired to field terminations and include surge arrestor and isolation.

3) Provide Ethernet modules for communications from PLC to I/O, and to SCADA. Provide EN2T Ethernet modules; one each for PLC I/O communications network and one for HMI/PLC communications network.

4) Provide all work and programming to incorporate MFS system graphics onto the Owner’s existing Wonderware SCADA system. Provide all necessary drivers and software updates.

5) Ethernet Switch Manufacturer and Product: a) N-Tron 716TX having (16) 10/100BASE-TX ports.

f. MSS to coordinate firmware revision with Owner at time of supply.

g. PLC Manufacturers and Products: Refer to Section 40 99 90, Package Control Systems.

h. HMI: Provide an industrial panel-mounted PC preloaded with Wonderware In-Touch HMI software for local control and monitoring from the MFS main control panel. 1) MSS to provide complete applications software and

graphics for Industrial panel-mounted PC. Graphics shall be the same as those created for the Owner’s SCADA system HMI.

2) Industrial Panel mounted PC minimum requirement: a) 17-inch color TFT LCD display. b) Fanless cooling system design. c) Minimum 100GB hard drive, (2) USB ports, and

(1) DVD-RW drive.

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d) Manufacturer: Arista, or approved equal. 3) MSS to coordinate version with Owner at time of supply. At

a minimum provide Wonderware In-Touch 10.0HMI software.

i. The HMI software of the plant SCADA system will be Wonderware. This software is existing and programming will be provided by the Contractor. Provide a copy of all Wonderware graphic screens developed for the MF Control Panel OIU to the Contractor for incorporation to the Plant Wonderware SCADA system. The plant SCADA software will be programmed to monitor and provide supervisory control of the Membrane Filtration control system. Complete operation of each membrane train shall be possible at the OIU at the main MF Control Panel or at the plant SCADA HMI graphical screen. The Proposer shall assist the Contractor in programming the SCADA HMI computer. Provide for Owner and Engineer input into graphics, displays, etc.

3. The Proposer shall be responsible for the proper sizing, programming and operation of the associated control equipment to adequately protect and control the equipment specified in this Section.

4. Instrumentation and Monitoring Equipment: a. Provide turbidimeters, laser turbidimeters, pH/ORP meters, flow

meters, and related appurtenances mounted in accessible locations.

b. Electromagnetic Flow Meters: 1) Provide for each membrane train and each backwash flow as

shown on the P&IDs. 2) Electromagnetic flow meters shall use pulsed dc type coil

excitation principle with high impedance Type 316 stainless steel electrodes and shall be designed for use in potable water. 120Vac 60-Hz power, remote wall mounted IP67/NEMA 4X transmitter, isolated 4 to 20 mA DC signal type output, minimum of 60 feet of IP 68 rated transmitter to element interconnecting cable, Type 316L stainless steel ANSI 150 pound flanges and grounding rings, straps and mounting brackets, epoxy coated exterior surfaces. Minimum accuracy including transmitter of plus or minus 0.5 percent of actual rate between 10 percent and 100 percent of design flow. Transmitter shall have LCD display with adjustable parameter access using a keypad or other non-intrusive means.

3) Provide factory calibration certificate for each meter. 4) Manufacturers and Products:

a) ABB Automation; Magmaster. b) Emerson Process Management Rosemount Division;

Model 8705 flow element and Model 8732 transmitter.

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c) Endress & Hauser; Promag 53 series. c. Pressure/Differential Pressure Transmitters:

1) General: a) Function:

(1) Measure pressure or differential pressure as shown on P&IDs.

(2) Transmit signal proportional to either differential pressure or pressure, as applicable.

b) Type: (1) Electronic variable capacitance or silicon strain

gauge. (2) Two-wire transmitter; “smart electronics”.

c) Parts: Transmitter and accessories. 2) Performance:

a) Range: As required. b) Accuracy: Plus or minus 0.10 percent of span, unless

otherwise noted. c) Process Operating Temperature: Minus 40 degrees F

to plus 250 degrees F. d) Humidity: 0 to 100 percent relative humidity.

3) Features: a) Linear or square-root output, user-configurable. b) Adjustable damping. c) LCD indicator. d) Display in either percent or engineering units, field

configurable. e) Wetted Metallic Parts: Type 316 stainless steel, unless

otherwise noted. f) Includes drain/vent valves; process flanges and

adapters, and process isolating diaphragm. g) Wetted O-Rings: Glass-filled TFE, graphite-

filled PTFE, or Viton, unless otherwise noted. h) Bolts and Nuts (if required): Type 316 stainless steel. i) Fill Fluid: Silicone.

4) Process Connections: a) Line Size: 1/2 inch. b) Connection Type: FNPT.

5) Signal Interface: a) 4 mA to 20 mA dc output with digital signal based on

HART protocol. (1) Nominal Maximum Loop Resistance with

External 24V dc Power Supply: 550 ohms. 6) Enclosure:

a) Type: NEMA 4X. b) Materials: Coated aluminum.

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c) Bracket and Accessories: Stainless steel; suitable for mounting transmitter to panel or 2-inch pipe.

7) Accessories: a) Three-valve manifold.

(1) Includes one equalization and two isolation valves.

(2) Type 316 stainless steel. 8) Manufacturers and Products:

a) Rosemount; Model 2088. b) Endress and Hauser; Cerebar.

d. Pressure Switch: 1) General:

a) Function: Monitor pressure, activate switch at set point, and deactivate switch at reset point.

b) Type: (1) Piston-actuated. (2) Both set point and deadband (the differential

between set point and reset point) adjustable. 2) Performance:

a) Set Point: (1) As required. (2) Repeatability: Plus or minus 1 percent of range.

b) Deadband: Adjustable within nominally 25 percent and 85 percent of range.

c) Overpressure Proof Pressure: (1) Pressure psi Ranges: At least 400 percent of

rated maximum static pressure. (2) Pressure Inches of Water Ranges: 20 psig. (3) Compound Range: 250 psig. (4) Vacuum Range: 250 psig.

3) Features: a) Actuator Seal: Buna N. b) Adjustable deadband. c) Mounting: Surface.

4) Process Connection: a) 1/4 inch NPT female connections. b) Materials: Type 316 stainless steel.

5) Enclosure: NEMA 4X. 6) Signal Interface: SPDT, rated for 10 amps minimum at

120V ac. 7) Manufacturers and Products: Ashcroft; L or P Series

e. Rotameters: a) Measure smaller flows and provide local indication

only.

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b) ABB series 10A4500 or Brooks GT 1100 Series. Alternative manufacturer must be approved by the Engineer prior to installation.

f. Pressure Gauges: a) General:

(1) Function: Local pressure indication. (2) Type: Bourdon tube element.

b) Performance: (1) Scale Range: As noted. (2) Accuracy: Plus or minus 0.50 percent of full

scale. c) Features:

(1) Dial: 4-1/2 inch diameter (2) Pointer Vibration Reduction: Required. (3) Case Material: Black thermoplastic. (4) Materials of Wetted Parts: Stainless steel. (5) Pointer: Adjustable by removing ring and

window. (6) Window: Glass or acrylic. (7) Threaded reinforced polypropylene front ring. (8) Case Type: Solid front with blow-out back.

d) Process Connection: (1) Mounting: Lower stem. (2) Size: 1/2-inch MNPT.

e) Accessories: (1) Throttling Device: Required.

(a) Type suitable for the intended service. (b) Install in gauge socket bore.

f) Manufacturers and Products: Ashcroft; Duragauge Model, 1279/Model, 1279 PLUS.

g. Temperature Element and Transmitter: a) 100 Ohm Platinum 3-wire RTD sensor within sealed

Type 316 Stainless steel sheath, mounting within ¼-inch tapered bore Type 316 stainless steel thermowell, DC loop powered, IP67/NEMA4X housed transmitter, isolated 4 to 20 mA DC output, min. accuracy of plus or minus 0.25 percent of reading.

b) Provide factory calibration certificate for each device. c) Manufacturer: Rosemount Model 3144, Foxboro, or

equal. Alternative manufacturer must be approved by Engineer prior to installation.

h. Turbidity Element and Transmitter: 1) General:

a) Type: Light scatter detection measurement using 90-degree scatter photocell detector.

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b) Function: Continuously measure, indicate, and transmit signals proportional to turbidity of raw water and membrane filtrate from each train.

c) Parts: Element, transmitter, interconnecting cable, mounting hardware, and expendables.

d) Each turbidimeter shall be integrated with MFS PLC for monitoring, data recording, and alarm/shutdown.

e) Turbidimeters shall obtain sample water by gravity flow from source and route wastewater to drain by gravity flow.

f) Provide one turbidimeter for each membrane filtration equipment train.

g) Provide one turbidimeter for membrane system influent quality monitoring.

2) Performance: a) Range:

(1) Membrane System Influent: 0 to 100 NTU. (2) Membrane Filtrate: 0 to 1 NTU.

b) Resolution: 0.0001 NTU. c) Repeatability: Plus or minus 1.0 percent or plus or

minus 0.002 NTU, whichever is greater. d) Response Time: For full scale step change, 90 percent

response in 5 minutes at 250 milliliters per minute of flow.

e) Required Flow: 250 to 750 milliliters per minute. f) Sample Fluid Temperature: 32 degrees F to 122

degrees F. g) Operating Temperature: 32 degrees F to

104 degrees C. 3) Element: Internal bubble trap and vent. 4) Transmitter:

a) Features: (1) Four-digit display. (2) Capability to display results from a minimum of

eight turbidimeters on single output screen. b) Signal Interface:

(1) Output: 4 to 20 mA dc for load impedance of 500 ohms minimum.

(2) Alarm Contacts: Two independent alarm set points, each adjustable over full range.

c) Enclosure: (1) Type: NEMA 4X. (2) Mounting: Wall mounted.

5) Cable: 20 feet. 6) Manufacturer and Product: Hach Company; Model 1720E.

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i. Laser Turbidimeter: 1) Type: Laser type for membrane integrity test. 2) Parts: 660-nanometer laser diode, fiber optics, and

photomultiplier tube. 3) Function: To allow turbidity measurement of membrane

filtrate from each independent membrane train. 4) Turbidimeter shall obtain sample water by gravity flow

from source and route wastewater to drain by gravity flow. 5) Manufacturer and Product: Hach Company; FilterTrak 660.

j. Temperature/pH Transmitter: 1) General:

a) Provide pH and ORP elements and transmitters as shown on the P&IDs

b) Function: Continuously, measure, indicate, and transmit water temperature and pH or ORP of process streams.

c) Parts: Analyzer/transmitter unit, mounting hardware, sample tubing and connectors, reagent bottle, and expendables.

2) Service: a) Measurement Type: pH or ORP and water

temperature. b) Sample Flow: 500 milliliters per minute. c) Sample Supply: Continuous. d) Sample Temperature Range: 32 degrees F to

100 degrees F. 3) Performance:

a) pH Range: 0 to 14 pH. b) ORP Range: Minus 1400 mV to plus 1400 mV. c) Temperature: 32 degrees F to 100 degrees F. d) Sensitivity: 0.01 pH units, 0.1 degree. e) Response Time: 4 seconds, maximum. f) Accuracy: 1 percent of range.

4) Features: a) Temperature Compensation: Automatic for sample

temperatures between 32 degrees F and 100 degrees F.

b) Display: LCD. c) Reagent Storage: 7-day supply bottle.

5) Instrument Piping Connections: Pre-piped; sample in, sample drain, and overflow drain.

6) Signal Interface: Outputs: Isolated 4 to 20 mA dc for load impedance 0 to 800 ohms minimum for 24V dc supply without load adjustment.

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7) Enclosure: a) Electronics: NEMA 4X. b) Instrument Mounting: Wall panel mounted.

k. Manufacturer and Product: Hach Company; GLI Series with SC100 transmitter.

l. General Instrumentation and Monitoring Equipment Requirements: 1) Provide 40 mm diameter stainless steel identification tags

with punched markings for each field-mounted device. Permanently attach the tags to the devices with stainless steel lightweight chain.

2) All four wire instrument AC supply circuits are to be supplied with local, watertight, corrosion-resistant disconnect switch, to be installed by the Contractor within 10 feet of the instrument’s final location.

3) For all Proposer provided instrumentation and monitoring equipment, provide all necessary components and fittings including, but not limited to standard and dielectric unions, grounding rings and straps, gaskets, bolts, reducers, meter body and transmitter supports.

4) Furnish all other instrumentation required to have a complete, operating system as described in this Document. These items may include gauges, switches, sensors, etc. These items should be of high quality, suitable for continuous, low-maintenance operation in a damp, hot, industrial environment.

K. Electrical: Refer to Section 26 20 00, Low-Voltage AC Induction Motors.

L. Accessories:

1. Lifting Lugs: Provide suitably attached for equipment assemblies and components weighing over 100 pounds.

M. Extra Materials:

1. Furnish, tag, and box for shipment and storage the following at a minimum: a. Jigs, fixtures, clamps lifting beams, hooks, and other apparatus

required to facilitate removal, disassembly, re-assembly and installation of each item of equipment within system.

b. Two sets of new tools required for removal, disassembly, reassembly, installation, operation, and maintenance of each specialty item of equipment within MFS (e.g., specialty tool for removal of membrane module).

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c. Two repair kits for sealing off damaged membrane fibers within membrane module.

d. Reagents/chemicals and calibration sets as specified for individual equipment items or instruments.

e. One shelf spare CIP recirculation pump.

2.07 FUNCTIONAL REQUIREMENTS

A. Provisions shall be made for both LOCAL and REMOTE operations for all controlled equipment.

1. Local Operation: All controlled equipment will each have a local ON/OFF/REMOTE hand switch located close to it. For controlled equipment with adjustable speed drives, a local speed potentiometer shall be provided as well. a. Local control is for maintenance only or local operation by the

operator. 2. Remote operation shall be provided by PLC controls. Remote operation

shall include the following functions: a. For each train, provide AUTO/OFF hand switch, START/STOP

pushbuttons, and “IN AUTO OPERATION” indicating light. Locate these devices on the panel front.

b. Auto mode, which includes startup and shutdown sequences and steady-state automatic operation: 1) Include interlocks as appropriate for safe operation and for

equipment protection. 2) Information from other systems in the Water Treatment

Plant (Facility) and from other systems within the Membrane System will be obtained from an Ethernet interface between all PLCs and the Plant SCADA system. Exchange of data between the plant SCADA control system and the Membrane System PLCs shall include, but not limited to: a) All control set points. b) All alarms. c) All measured parameters. d) Status of all equipment. e) In auto status of all items. f) Position of control valves.

3) Various AUTO Mode Parameters shall be adjusted from: a) An Operator Interface Unit (OIU) on the front of the

main control panel. b) At the graphic screens of the plant SCADA HMI

computers.

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4) Create a FAIL alarm for each controlled device; i.e., if a device is commanded to run from the control panel, but is not confirmed ON within a preset time, create the FAIL alarm.

B. The Proposer’s Control System shall be designed to perform the following functions as a minimum:

1. Monitor and trend operational data for feed and filtrate water for each train including the following at a minimum: a. Pressure. b. Flow Rate. c. Temperature.

2. Monitor and trend operational data for other membrane system components for each train including the following at a minimum: a. Transmembrane pressure. b. Backwash flow rate (air and water). c. Chemical flows for chemically enhanced backwashes. d. CIP solution flow rate. e. Totalized flow. f. Hours of Operation. g. Flux rate.

3. Control the sequence of backwashing, CEBs, and CIPs. 4. Store the backwashes (normal and CEB), air and water backwash

duration, and perform calculations to determine the recovery efficiency. 5. Interrupt operation and/or sound alarm for high transmembrane

pressure, high membrane filtered water turbidity, high membrane filtered water particle counts, failed membrane integrity test, low filtered water flow, high prefilter differential pressure, high or low filtrate pH, and feed or filtrate pump failure, and any other parameters as per Manufacturer’s standard.

6. Automatic control of membrane integrity tests. 7. Adjust flow through membrane train in response to a manual input

through the control system from operator. 8. Manual START/STOP and Automatic flow-pace feed or filtrate pumps. 9. Shutdown train, and alarm upon failure of any defined critical parameter

or component. 10. Record and alarm power failures, and transfers to and from backup

power. 11. Provide other features as required by the system for unattended

operation, to meet specified performance requirements, and to meet the monitoring requirements.

12. During operation of the Membrane Filtration System, the Owner’s operators shall select and enter the desired flow rate for each train using the OIU on the main control panel or via the graphic screen on the plant SCADA HMI computer.

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C. Panel Mounted Controls and Indications:

1. For each train, provide AUTO/OFF hand switches, START/STOP pushbuttons, and “IN AUTO OPERATION” indicating light. See Paragraph Functional Requirements above.

2. Provide an OIU mounted on main control panel front. a. OIU shall allow operator to adjust all parameters related to

automatic operation, including speed of adjustable speed drives. b. OIU shall display all equipment status and alarm conditions

related to automatic operation.

D. Security:

1. Provide security features to access the OIU as follows: a. View graphics only. b. Issue commands. c. Adjust set points. d. Re-configure software.

2.08 FACTORY FINISHING

A. Prepare, prime, and finish coat as follows:

1. Ferrous Metal (nonstainless steel) Surfaces in Contact with Effluent: a. SP5, white metal blast cleaning surface preparation. b. Three coats, 3 MDFTPC NSF 61 epoxy.

2. Ferrous Metal (nonstainless steel) Surfaces Exposed: a. SP10, near white blast cleaning surface preparation. b. One coat, 2.5 MDFT, epoxy primer. c. One coat, 4 MDFT, high build epoxy; and d. One coat, 3 MDFT, polyurethane enamel.

3. Plastic (PVC, CPVC and FRP without integral UV-resistant gel coat) Surfaces Directly Exposed to Sunlight: a. Hand sand plastic surfaces to be coated with medium grit

sandpaper to provide tooth for coating system. b. Two coats, 320 SFPGPC, acrylic latex semigloss.

2.09 SOURCE QUALITY CONTROL

A. Factory Inspections: MSS shall inspect each component of MFS, including control panels for required construction, electrical connection, and intended function.

B. Factory Tests:

1. Test entire control system actually furnished including panels, hardware, and software configuration.

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2. Perform unwitnessed factory test of entire system prior to a witnessed factory test.

3. Tests Witnessed by Owner: a. Factory test specified herein. b. Factory test for plastic header components supplied within

membrane system. 4. Test for proper alignment, quiet operation, proper connection, pumping

capacity, and satisfactory performance. 5. Functional Test:

a. Perform manufacturer’s standard, motor test on equipment (feed pumps only).

b. Include vibration test. c. Dynamically balance rotating parts of each pump, blower and

drive units before final assembly. Limits: 1) Driving Unit Alone: Less than 80 percent of NEMA MG 1

limits. 2) Complete Rotating Assembly Including Blower, Coupling,

Drive Unit, and Motor: Less than 90 percent mils of limits established in Hydraulic Institute Standards.

6. Performance Tests: In accordance with the following: a. ANSI/AWWA B110-09 b. ASME PTC 10. c. Hydraulic Institute Standards.

7. See Section 40 99 90, Package Control Systems, for approvals required prior to shipment and additional requirements.

8. Motor Test: In accordance with Section 26 20 00, Low-Voltage AC Induction Motors (factory test for feed and RF pumps, on-site testing for feed pumps only).

9. Provide written certification of tests to Contractor prior to shipping equipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. MSS shall furnish installation instructions and recommendations to Contractor. Contractor shall install MFS in accordance with MSS’s instructions and recommendations.

3.02 LIQUIDATED DAMAGES

A. The MSS shall be assessed liquidated damages for failure to meet the time limit for each item listed in the schedule described in Part 1 of this specification.

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B. If submittal is deemed incomplete by the Owner, the MSS shall have 7 days from notification to submit the missing portions of the submittal before being assessed liquidated damages.

C. Additional time for each phase of the project may be granted at the Owner’s discretion.

D. The liquidated damages cannot exceed 10 percent of the total contract amount.

E. Liquidated damages shall be waived if the delay is deemed not the fault of the MSS, or are due to outside circumstances beyond the reasonable control of the MSS.

F. Amounts of liquidated damages are:

1. $500 USD per day late on each of the submittals

2. $1000 USD per day late on equipment delivery.

3.03 FIELD QUALITY CONTROL

A. General:

1. MSS shall conduct testing with assistance from Contractor. 2. MSS and Contractor shall arrange times for testing and startup

activities, however, Contractor shall confirm times are acceptable to Owner.

3. Upon issuance of Certification of Proper Installation, MSS shall coordinate with Contractor to perform functional testing of the MFS.

4. Calibrate instruments, including pressure differential transmitters, process analyzers, and flowmeters in MSS’s scope of supply.

5. Owner will provide feed water for use in Functional Test if requested by Contractor.

6. Complete functional testing to satisfaction of Owner prior to commencing Initial Performance Test.

B. Functional Test: Demonstrate effectiveness of the following system components and features:

1. Operate MFS valves, controls, and other devices to ensure they are functional.

2. Conduct control system functional testing as required in Section 40 99 90, Package Control Systems.

3. Automatic START/STOP, flow control, and level control of membrane system feed pumps using SCADA.

4. Automatic START/STOP and flow control of membrane trains using SCADA.

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5. Manual flow control using membrane train HMI(s) and PLC(s). 6. Automatic backwashing (normal and CW) at various time intervals. 7. Automatic shutoff and alarm for various failure modes for each

membrane train and for entire MFS. 8. START and STOP of air system. 9. Automatic membrane integrity test system. 10. Determination of clean water permeability of each membrane train and

temperature correction of clean water permeability for each train. 11. Monitoring and recovery of operating data. 12. Monitoring and control from remote workstation. 13. Automatic switchover from normal power to emergency power, and

emergency power to normal power. 14. Control functions, both at local system and remote workstation. 15. Operation of chemical cleaning systems. 16. Operation of monitoring instruments. 17. Visual or sonic inspection of membrane modules for integrity (bubble

point testing). 18. I/O to/from PCS and plant-wide SCADA.

C. Initial Performance Test:

1. General: a. During Initial Performance Test, Owner shall have option of

collecting samples for independent analyses to confirm measurements and analyses.

b. Owner shall have option of witnessing testing performed. c. MSS shall notify Owner a minimum of two weeks in advance of

testing. d. MSS shall provide Initial Performance Test report within 7 days

of completion of test period. 2. Operate system continuously over a 30-day test period, and collect and

summarize data to demonstrate system meets Initial Performance Test requirements for parameters listed below.

3. Compliance with requirements of Specification shall be determined for each calendar day. To successfully pass test, MFS shall comply with the following requirements for each of the 30 consecutive days of Initial Performance Test: a. Filtrate Production Capacity:

1) System meets design filtrate production capacity requirements as defined in Article, Performance Requirements when operated at or below specified maximum instantaneous flux rate.

2) Capacity shall be adjusted for actual feed water temperature in event actual feed water temperature is less than specified range.

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b. Recovery: System meets requirements for recovery and for membrane system recovery.

c. Pressure Limitations: System operates within specified TMP limit and system provides adequate filtrate discharge pressure to discharge to plant break tank as specified.

d. Instantaneous and Average Flux Rate: 1) Shall not exceed specified maximum. 2) Backwash (normal and CW) and membrane integrity test

times shall be included in determination of average flux rate specified.

3) Flux rate for system shall not exceed average flux rate corresponding to train instantaneous flux rate.

e. Membrane Integrity Test System: Operate integrity test at a frequency of once every 24 hours.

f. Membrane Filtrate Quality: Meets requirements for turbidity and particle concentrations as specified in Paragraph, Membrane Filtrate Quality.

g. CW: Conduct at an average and maximum frequency as specified. h. Clean-in-Place: Perform at least once on each membrane train

during test period. i. Cleaned Membrane Permeability and Post-CIP Fouling Rate:

Following each CIP, calculate Cleaned Membrane Permeability and Post-CIP Fouling Rate.

j. CW and CIP Spent Solution Discharge: 1) . 2) Each discharge shall comply with requirements for

discharge to sanitary sewer. k. Energy Usage: Monitor average power consumption and

maximum power demand for MFS for duration of test period. l. Provide control system Performance Testing as defined in

Section 40 99 90, Package Control System. 4. Successful Test:

a. Successful completion of Initial Performance Test shall be defined as 30 continuous days of operation without a major failure in system and demonstration that system meets performance requirements established herein.

b. Downtime resulting from Owner’s operation will not be counted against criteria of “continuous days of operation”.

5. Test Failure: a. A major failure in MFS is one that decreases system capacity

below 75 percent of design capacity for more than 24 hours, or requires CWs or CIPs more often than as specified in Article, Performance Requirements.

b. For control systems, a major failure is an event that requires operator intervention to restart or to re-establish normal system operation beyond that described above.

402449A.GN1


c. If MFS fails to successfully complete Initial Performance Test, MSS and Contractor shall have option of repeating test over a second 30-consecutive-day period.

6. If system fails to successfully complete Initial Performance Test during second test period or in opinion of Owner, MSS’s initially supplied and installed MFS cannot meet performance requirements specified herein, MSS shall submit written plan within 14 days to modify, supplement, or remove and replace system as required to meet performance requirements at sole cost of MSS. Following acceptance of plan a third Initial Performance Test period shall be completed over 30-day continuous period.

7. If MFS, as modified or supplemented, fails to meet third Initial Performance Test, MSS shall remove initial system and Owner will select and install alternative membrane system. Cost of system removal and alternative system procurement and installation shall be responsibility of MSS. This requirement shall be secured by MSS’s Performance and Payment Bond.

3.04 MANUFACTURER’S SERVICES

A. Manufacturer’s Representative: Present at Site or classroom designated by Owner for minimum person-days listed below, travel time excluded. These hours represent a minimum level of effort that shall be included in the MSS proposal for these activities and are not in addition to normal service and support.

1. 4 person-days during 1 trip unloading of MFS equipment. 2. 2 person-days over 1 trip for attendance at design meetings. 3. 1 person-day over 1 trip for attendance at construction meetings. 4. 16 person-days over 4 trips for MFS installation assistance. 5. 4 person-days over 1 trip for training Owner’s operators. 6. 4 person-days over 1 trip for assistance during functional testing 7. 8 person-days over 2 trips for assistance during startup activities. 8. MSS shall also provide standard rates for the services of a qualified

representative to visit during MTP.

B. Telephone:

1. Provide telephone support by means of a toll-free phone number for a minimum period of 10 years following installation and startup.

2. Provide a list of three or more names of individuals qualified to support operation, and provide pager numbers for these individuals, if available. At least one of the listed individuals shall be available at all times including nights, weekends, and holidays in the event of an emergency.

END OF SECTION

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