CLEAN WATER SERVICES...ANSI B74.18 Grading of CertainAbrasive Grain on CoatedAbrasive MaterialASTM...

CONTRACT DOCUMENTS FOR THE

CONSTRUCTION OF

DURHAM AWWTF

FOG TANK RETROFIT PROJECT

ENGINEER PROJECT# 154061

OWNER PROJECT# 6992

CLEAN WATER SERVICES

BID DOCUMENTS

VOLUME 2 OF 3

TECHNICAL SPECIFCATIONS

Divisions 09-17

October 2020

TABLE OF CONTENTS

Durham AWWTF – FOG Tank Retrofit Project Table of ContentsEngineer Project Number: 154061 Owner Project Number: 6992

1

VOLUME 1 OF 3

DIVISION 00 GENERAL REQUIREMENTS

00030 Advertisement to Bid

00100 Instructions to Bidders

00300 Bid Forms

00500 Agreement

00610 Performance Bond Form

00630 Payment Bond Form

00700 Standard General Conditions of the Construction Contract

00800 Supplementary Conditions

00810 Oregon Prevailing Wage Rates

DIVISION 01 GENERAL REQUIREMENTS

01012 Partnering

01110 Summary of Work

01140 Work Restrictions and Sequencing

01292 Schedule of Values

01320 Web-Based Construction Management

01324 CPM Construction Schedule

01329 Safety Plan

Safety Plan Attachment A: Hot Permit

Safety Plan Attachment B: OSHA Confined Spaces and permit spaces

01330 Submittal Procedures

01350 Special Procedures

01352 Alteration Project Procedures

01424 Abbreviations

01450 Quality Control

01455 Special Inspections, Observations, and Testing

01500 Temporary Facilities and Controls

01505 Mobilization and Demobilization

01530 Protection of Existing Facilities

01532 Site Conditions Surveys

01555 Site Access and Storage

01560 Temporary Environmental Controls

01570 Erosion and Sediment Control

01600 Product Requirements

01610 Project Design Criteria

01612 Design Requirements for Non-Structural Components and Non-Building Structures

01640 Manufacturer's Services

01732 Cutting and Patching

01738 Selection Demolition

01756 Testing and Facility Startup

01770 Closeout Procedures

TABLE OF CONTENTS


2

01782 Operation and Maintenance Data

DIVISION 02 EXISTING CONDITIONS

02050 Demolition

02100 Site Preparation

02200 Earthwork

02370 Soil Stabilization

02500 Paving and Paving Repair

02631 Catch Basins

02632 Buried Storm Sanitary and Drain Piping

DIVISION 03 CONCRETE

03200 Concrete Reinforcement

03300 Cast-In-Place Concrete

03600 Grout

03732 Concrete Cleaning and Repair

DIVISION 04 MASONRY

04200 Unit Masonry

DIVISION 05 METALS

05502 Anchors to Concrete

05505 Miscellaneous Metalwork

05520 Metal Railings

05530 Metal Gratings and Stair Treads

DIVISION 07 THERMAL AND MOISTURE PROTECTION

07100 Waterproofing and Moistureproofing

07900 Sealants

TABLE OF CONTENTS


3

VOLUME 2 OF 3

DIVISION 09 FINISHES

09900 Painting and Coating

DIVISION 11 EQUIPMENT

11000 General Requirements for Equipment

11002 Rigid Equipment Mounts

11131 FOG Screening Equipment

11200 Activated Carbon Adsorption Odor Control Equipment

11315 Progressing Cavity Pumps

11385 Positive Displacement Rotary Lobe Pumps

DIVISION 13 SPECIAL CONSTRUCTION

13122 Pre-Engineered Metal Building

13201 Shop Fabricated Multi-Column Hopper-Bottom Welded SS FOG Storage Tank

DIVISION 14 CONVEYING SYSTEMS

14611 Monorail Hoists

DIVISION 15 MECHANICAL

15050 Piping Systems

15060 Piping System Identification

15061 Steel Pipe

15062 Ductile Iron Pipe

15064 Solvent Cement Welded PVC Pipe and CPVC Pressure Pipe

15065 Insulated Underground Piping

15066 Copper Process Pipe and Tubing

15075 Joint Gaskets

15085 Piping Connections

15090 Expansion Joints and Flexible Metal Hose

15095 Piping Appurtenances

15096 Hangers and Supports for Process Pipping

15097 Seismic Restraints for Piping

15110 Eccentric Plug Valves for Liquid Service

15120 Nonclog Ball Check Valves

15136 Knife Gate Valves

15147 Solenoid Valves

15184 Manual Actuators

15185 Electric Motorized Actuators

15250 Process Piping and Equipment Insulation

TABLE OF CONTENTS


4

DIVISION 16 ELECTRICAL

16050 Common Work Results for Electrical

16052 Hazardous Classified Area Construction

16060 Grounding and Bonding

16070 Hangers and Supports

16075 Electrical Identification

16123 600 Volt or Less Wires and Cables

16130 Conduits

16134 Boxes

16140 Wiring Devices

16150 Low Voltage Wire Connections

16222 Low Voltage Motors up to 500 Horsepower

16262 Variable Frequency Drives 0.5-50 Horsepower

16411 Disconnect Switches

16510 Lighting: LED Luminaires

16950 Field Electrical Acceptance Tests

DIVISION 17 INSTRUMENTATION

17050 Basic Measurement and Control Instrumentation Materials and Methods

17101 Control Loop Descriptions

17316 Flow Rotameters

17401 Diaphragm and Annular Seals

17402 Instrument Valves

17403 Pressure Vacuum Switches

17404 Pressure Gauges

17710 Control Systems: Panels, Enclosures, and Panel Components

17901 Instrument List

17903 Input/Output List

VOLUME 3 OF 3

DRAWINGS

Durham AWWTF – FOG Tank Retrofit Project Coating Systems

Engineer Project Number: 154061

Owner Project Number: 6992

09900 - 0

SECTION 09900

COATING SYSTEMS

PART 1 GENERAL

1.01 DESCRIPTION

A. SCOPE:

1. This Section specifies coating systems, surface preparations, and application

requirements for coating systems.

B. Definitions:

1. Specific coating terminology used in this Section is in accordance with definitions

contained in ASTM D16, ASTM D3960, and the following definitions.

a. Definitions:

1) Abrasive: Material used for blast cleaning, such as sand, grit or shot.

2) Abrasive Blast Cleaning: Cleaning/surface preparation by abrasive propelled

at high speed.

3) Anchor Pattern: Profile or texture of prepared surface(s).

4) ANSI: American National Standards Institute.

5) Bug Holes: Small cavities, usually not exceeding 15 mm in diameter, resulting

from entrapment of air bubbles in the surface of formed concrete during

placement and compaction.

6) Coating/Paint/Lining Thickness: The total thickness of primer, intermediate

and/or finish coats.

7) Coating System Applicator (CSA): A generic reference to the specialty

subcontractor or subcontractors retained by the Contractor to install the

coating systems specified in this Section.

8) Coating System Manufacturer (CSM): Refers to the acceptable coating

system manufacturer, abbreviated as the CSM.

9) Coating System Manufacturer’s Technical Representative(s) (CTR): Refers to

the technical representative(s) of the acceptable Coating System

Manufacturer and is abbreviated as CTR.

10) Dew point: Temperature of a given air/water vapor mixture at which

condensation starts.

11) Dry Film Thickness (DFT): Depth of cured film, usually expressed in mils

(0.001 inch). Use this definition as opposed to existing definition.

12) Drying Time: Time interval between application and curing of material.

13) Dry to Recoat: Time interval between application of material and ability to

receive next coat.

14) Dry to Touch: Time interval between application of material and ability to

touch lightly without damage.

15) Feather Edging: Reducing the thickness of the edge of paint.

16) Feathering: Operation of tapering off the edge of a point with a comparatively

dry brush.




09900 - 1

17) Field Coat: The application or the completion of application of the coating

system after installation of the surface at the site of the work.

18) Hold Point: A defined point, specified in this Section, at which work shall be

halted for inspection.

19) Holiday: a discontinuity, skip, or void in coating or coating system film that

exposes the substrate.

20) Honeycomb: Segregated condition of hardened concrete due to non-

consolidation.

21) ICRI: International Concrete Repair Institute.

22) Incompatibility: Inability of a coating to perform well over another coating

because of bleeding, poor bonding, or lifting of old coating; inability of a

coating to perform well on a substrate.

23) Laitance: A layer of weak, non-durable concrete containing cement fines that

is brought to the surface through bleed water because of concrete finishing

and/or over-finishing.

24) Mil: 0.001 inch.

25) NACE: National Association of Corrosion Engineers.

26) Overspray: Dry spray, particularly such paint that failed to strike the intended

surface.

27) Pinhole: A small diameter discontinuity in a coating or coating system film

that is typically created by outgassing of air from a void in a concrete

substrate resulting in exposure of the substrate or a void between coats.

28) Pot Life: Time interval after mixing of components during which the coating

can be satisfactorily applied.

29) Resurfacer/Resurfacing Material: A layer of cementitious and/or resin-base

material used to fill or otherwise restore surface continuity to worn or

damaged concrete surfaces.

30) Shelf Life: Maximum storage time for which a material may be stored without

losing its usefulness.

31) Shop Coat: One or more coats applied in a shop or plant prior to shipment to

the site of the work, where the field or finishing coat is applied.

32) Spreading Rate: Area covered by a unit volume of paint at a specific

thickness.

33) SSPC: The Society for Protective Coatings.

34) Stripe Coat: A separate coat of paint applied to all weld seems, pits,

nuts/bolts/washers and edges by brush. This coat shall not be applied until

any previous coat(s) have cured and, once applied, shall be allowed to cure

prior to the application of the subsequent coat(s).

35) Surface Saturated Dry (SSD): Refers to concrete surface condition where the

surface is saturated (damp) without the presence of standing water.

36) Tie Coat: An intermediate coat used to bond different types of paint coats.

Coatings used to improve the adhesion of a succeeding coat.

37) Touch-Up Painting: The application of paint on areas of painted surfaces to

repair marks, scratches, and areas where the coating has deteriorated to

restore the coating film to an unbroken condition.




09900 - 2

38) TPC: Technical Practice Committee.

39) Volatile Organic Compound (VOC) Content: The portion of the coating that is a

compound of carbon, is photochemically reactive, and evaporates during

drying or curing, expressed in grams per liter (g/l) or pounds per gallon

(lb/gal).

40) Immersion: Refers to a service condition in which the substrate is below the

waterline or submerged in water or wastewater at least intermittently if not

constantly.

41) Weld Splatter: Beads of metal scattered near seam during welding.

42) Wet Film Thickness (WFT): The primer or coating film’s thickness immediately

following application. Wet film thickness is measured in mils or thousandths

of an inch (0.001 inch) and is abbreviated WFT.

1.02 QUALITY ASSURANCE

A. References:

1. This section contains references to the following documents. They are a part of this

section as specified and modified. Where a referenced document contains

references to other standards, those documents are included as references under

this section as if referenced directly. In the event of conflict between the

requirements of this section and those of the listed documents, the requirements of

this section shall prevail.

2. Unless otherwise specified, references to documents shall mean the documents in

effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective

date of the Agreement if there were no Bids). If referenced documents have been

discontinued by the issuing organization, references to those documents shall mean

the replacement documents issued or otherwise identified by that organization or, if

there are no replacement documents, the last version of the document before it was

discontinued. Where document dates are given in the following listing, references to

those documents shall mean the specific document version associated with that

date, regardless of whether the document has been superseded by a version with a

later date, discontinued, or replaced.

Reference Title

ANSI/ASC 29.4

Exhaust Systems

Abrasive Blasting Operations – Ventilation and Safe Practice

ANSI/NSF 61 Drinking Water System Components Health Effects

ANSI B74.18 Grading of Certain Abrasive Grain on Coated Abrasive Material

ASTM D16 Standard Terminology for Paint, Related Coatings, Materials, and Applications

ASTM D2200

(SSPC-VIS1)

Pictorial Surface Preparation Standards for Painting Steel Surfaces

ASTM D3960 Standard Practice for Determining Volatile Organic Compound (VOC) Content of Paints and

Related Coatings

ASTM D4262 Standard Test Method for pH of Chemically Cleaned or Etched Concrete Surfaces

ASTM D4263 Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method

ASTM D4414 Standard Practice for Measurement of Wet Film Thickness by Notch Gages




09900 - 3

Reference Title

ASTM D4417 Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

ASTM D4541 Standard Test Methods for Pull-Off Strength of Coatings On Metal Substrates Using

Portable Adhesion Testers

ASTM D4787 Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to Concrete

Substrates

ASTM D5162 Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating

on Metallic Substrates

ASTM D7234 Standard Test Method for Pull-Off Adhesion Strength of Coatings on Concrete Using

Portable Adhesion Testers.

ASTM E337 Standard Test Method for Measuring Humidity With a Psychrometer

ASTM F1869 Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor

Using Anhydrous Calcium Chloride

FS 595b Federal Standard Colors

ICRI 03732 Guideline for Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings,

and Polymer Overlays

NACE Publication 6D-163 A Manual for Painter Safety

NACE Publication 6F-163 Surface Preparation of Steel or Concrete Tank/Interiors

NACE Publication 6G-164 A Surface Preparation Abrasives for Industrial Maintenance Painting

NACE Standards January 1988 Edition of the National Association of Corrosion Engineers, TPC.

NACE Standard RP0188 Standard Recommended Practice – Discontinuity (Holiday) Testing of New Protective

Coatings on Conductive Substrates

NACE Standard RP0288 Standard Recommended Practice, Inspection of Linings on Steel and Concrete

NACE Standard RP0892 Standard Recommended Practice, Linings Over Concrete in Immersion Service

NACE Publication TPC2 Coatings and Linings for Immersion Service

NAPF 500-03 Surface Preparation Standard for Ductile Iron Pipe and Fittings in Exposed Locations

Receiving Special External Coatings and/or Special Internal Linings

NAPF 500-03-04 Abrasive Blast Cleaning for Ductile Iron Pipe

NAPF 500-03-05 Abrasive Blast Cleaning for Cast Ductile Iron Fittings

OSHA 1910.144 Safety Color Code for Marking Physical Hazards

OSHA 1915.35 Standards – 29CFR - Painting

SSPC Paint Application Specification No. 1.

SSPC-AB 1 Mineral and Slag Abrasives

SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel

SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages

SSPC-PA 9 Measurement of Dry Coating Thickness on Cementitious Substrates Using Ultrasonic Gages

SSPC-PA Guide 1 Guide for Illumination of Industrial Painting Project

SSPC-PA Guide 3 A Guide to Safety in Paint Application

SSPC-PA Guide 6 Guide for Containing Debris Generated During Paint Removal Operations

SSPC-PA Guide 11 Guide for Coating Concrete

SSPC SP1 Solvent Cleaning




09900 - 4

Reference Title

SSPC SP2 Hand Tool Cleaning

SSPC SP3 Power Tool Cleaning

SSPC SP5 White Metal Blast Cleaning

SSPC SP6 Commercial Blast Cleaning

SSPC SP7 Brush-Off Blast Cleaning

SSPC SP10 Near-White Blast Cleaning

SSPC SP11 Power Tool Cleaning to Bare Metal

SSPC SP12 Surface Preparation and Cleaning of Steel and Other Hard Materials by High and Ultra-High

Pressure Water Jetting Prior to Recoating

SSPC SP13 Surface Preparation of Concrete

SSPC-TR2 Wet Abrasive Blast Cleaning

SSPC-TU-3 Overcoating

SSPC-TU-4 Field Methods for Retrieval and Analysis of Soluble Salts on Substrates.

SSPC V2 Systems and Specifications: Steel Structures Painting Manual, Volume 2

SSPC-VIS 1 Visual Standard for Abrasive Blast Cleaned Steel

SSPC-VIS 3 Visual Standard for Power and Hand – Tool Cleaned Steel

SSPC-VIS 4 Visual Standards (Waterjetting)

SSPC-VIS 5 Visual Standards (Wet Abrasive Blast Cleaning)

WPCF Manual of Practice No.

17

Paints and Protective Coatings for Wastewater Treatment Facilities. Guide and Paint

Application Specifications.

B. Standardization:

1. Materials and supplies provided shall be the standard products of CSMs. Materials in

each coating system shall be the products of a single CSM.

2. The standard products of CSMs other than those specified may be acceptable when

it is demonstrated to the Construction Manager that they are equal in composition,

durability, usefulness, and convenience for the purpose intended. Requests for

consideration of CSMs other than those specified in this Section will be considered,

provided the following minimum conditions are met. Such requests are not a

substitution for submittals after the alternative CSMs have been considered and

accepted.

a. The proposed coating system shall use an equal or greater number of separate

coats to achieve the required total dry film thickness.

b. The proposed coating system shall use coatings of the same generic type as that

specified including curing agent type.

c. Requests for consideration of products from CSMs other than those specified in

this Section shall include information listed in paragraph 1.04, demonstrating

that the proposed CSM’s product is equal to the specified coating system.

d. The Contractor and the proposed alternative CSM shall provide a list of

references for the proposed product where the coating of the same generic type

has been applied. The reference list shall include the project name, city, state,




09900 - 5

owner, phone number of owner; coating system reference and number from this

Section 09900; type of facility in which it was used, generic type, and year

coating was applied.

C. Quality Control Requirements:

1. The Contractor is responsible for the workmanship and quality of the coating system

installation. Inspections by the Construction Manager or the CTR will not relieve or

limit the Contractor’s responsibilities.

2. The Contractor’s methods shall conform to requirements of this specification and the

standards referenced in this Section. Changes in the coating system installation

requirements will be allowed only with the written acceptance of the Construction

Manager before work commences.

3. Only personnel who are trained by the CTR specifically for this contract or who are

approved by the CSM specifically for this contract shall be allowed to perform the

coating system installation specified in this Section.

4. Contaminated, outdated, diluted materials, and/or materials from previously opened

containers shall not be used.

5. For repairs, the Contractor shall provide the same products, or products

recommended by the CSM, as used for the original coating.

6. The Contractor shall identify the points of access for inspection by the Owner or the

Construction Manager. The Contractor shall provide ventilation, ingress and egress,

and other means necessary for the Construction Manager’s personnel to access

safely the work areas.

7. The Contractor shall conduct the work so that the coating system is installed as

specified and shall inspect the work continually to ensure that the coating system is

installed as specified. Coating system work that does not conform to the

specifications or is otherwise not acceptable shall be corrected as specified.

8. The Contractor shall complete the Coating System Inspection Checklist, Form 09900-

A, for coating system installations. Follow the sequential steps required for proper

coating system installation as specified and as listed in the Coating System

Inspection Checklist. For each portion of the work, install the coating system and

complete sign-offs as specified prior to proceeding with the next step. After

completing each step as indicated on the Coating System Inspection Checklist, the

Contractor shall sign the checklist indicating that the work has been installed and

inspected as specified.

9. The Contractor shall provide written daily reports that present, in summary form, test

data, work progress, surfaces covered, ambient conditions, quality control inspection

test findings, and other information pertinent to the coating system installation.




09900 - 6

D. Inspection at Hold Points:

1. The Contractor shall conduct inspections at Hold Points during the coating system

installation and record the results from those inspections on Form 09900-A. The

Contractor shall coordinate such Hold Points with the Construction Manager such

that the Construction Manager may observe Contractor’s inspections on a scheduled

basis. The Contractor shall provide the Construction Manager a minimum of two (2)

hours of notice prior to conducting Hold Point Inspections. The Hold Points shall be

as follows:

a. Environment and Site Conditions. Prior to commencing an activity associated with

coating system installation, the Contractor shall measure, record, and confirm

acceptability of ambient air temperature and humidity as well as other conditions

such as proper protective measures for surfaces not to be coated and safety

requirements for personnel. The acceptability of the weather and/or

environmental conditions within the structure shall be determined by the

requirements specified by the CSM of the coating system being used.

b. Conditions Prior to Surface Preparation. Prior to commencing surface

preparation, the Contractor shall observe, record, and confirm that oil, grease,

and/or soluble salts have been eliminated from the surface.

c. Monitoring of Surface Preparation. Spot checking of degree of cleanliness,

surface profile, and surface pH testing, where applicable. In addition, the

compressed air used for surface preparation or blow down cleaning shall be

checked to confirm it is free from oil and moisture.

d. Post Surface Preparation – Upon completion of the surface preparation, the

Contractor shall measure and inspect for proper degree of cleanliness and

surface profile as specified in this Section 09900 and in the CSM’s written

instructions.

e. Monitoring of Coatings Application – The Contractor shall inspect, measure, and

record the wet film thickness and general film quality (visual inspection) for lack

of runs, sags, pinholes, holidays, etc. as the application work proceeds.

f. Post Application Inspection – The Contractor shall identify defects in application

work including pinholes, holidays, excessive runs or sags, inadequate or

excessive film thickness and other problems as may be observed.

g. Post Cure Evaluation – The Contractor shall measure and inspect the overall dry

film thickness. The Contractor shall conduct a DFT survey, as well as perform

adhesion testing, holiday detection, or cure testing as required based on the type

of project and the specific requirements in this Section 09900 and/or in the

CSM’s written instructions.

h. Follow-up to Corrective Actions and Final Inspection. The Contractor shall

measure and reinspect corrective coating work performed to repair defects

identified at prior Hold Points. This activity also includes final visual inspection

along with follow-up tests such as holiday detection, adhesion tests, and DFT

surveys.




09900 - 7

1.03 DELIVERY AND STORAGE

A. General:

1. Materials shall be delivered to the job site in their original, unopened containers.

Each container shall be properly labeled. Materials shall be handled and stored to

prevent damage to or loss of label.

2. Labels on material containers shall show the following information:

a. Name or title of product.

b. CSM's batch number.

c. CSM's name.

d. Generic type of material.

e. Application and mixing instructions.

f. Hazardous material identification label.

g. Shelf life expiration date.

3. Materials shall be stored in enclosed structures and shall be protected from weather

and excessive heat or cold in accordance with the CSM’s recommendations.

Flammable materials shall be stored in accordance with state and local

requirements.

4. Containers shall be clearly marked indicating personnel safety hazards associated

with the use of or exposure to the materials.

5. Material Safety Data Sheets (MSDS) for each material shall be provided to the

Construction Manager.

6. The Contractor shall store and dispose of hazardous waste according to federal, state

and local requirements. This requirement specifically addresses waste solvents and

coatings.

1.04 SUBMITTALS:

A. General:

1. Provide in accordance with Section 01330:

a. A copy of this specification section, with addendum updates included, and

referenced and applicable sections, with addendum updates included, with each

paragraph check-marked (✓) to indicate specification compliance or marked to

indicate requested deviations from specification requirements or those parts

which are to be provided by the Contractor or others. Check marks shall denote

full compliance with a paragraph as a whole. If deviations from the specifications

are indicated, and therefore requested by the Contractor, each deviation shall be

underlined and denoted by a number in the margin to the right of the identified

paragraph, referenced to a detailed written explanation of the reasons for

requesting the deviation. The Construction Manager shall be the final authority

for determining acceptability of requested deviations. The remaining portions of

the paragraph not underlined shall signify compliance on the part of the

Contractor with the specifications. Failure to include a copy of the marked-up

specification sections, along with justification(s) for requested deviations to the

specification requirements shall be cause for rejection of the entire submittal and

no further submittal material will be reviewed.




09900 - 8

b. CSM’s current printed recommendations and product data sheets for coating

systems including:

1) Volatile organic compound (VOC) data.

2) Surface preparation recommendations.

3) Primer type, where required.

4) Maximum dry and wet-mil thickness per coat.

5) Minimum and maximum curing time between coats, including atmospheric

conditions for each.

6) Curing time before submergence in liquid.

7) Thinner to be used with each coating.

8) Ventilation requirements.

9) Minimum atmospheric conditions during which the paint shall be applied.

10) Allowable application methods.

11) Maximum allowable moisture content.

12) Maximum shelf life.

c. Affidavits signed and sealed by an officer of the CSM’s corporation, attesting to

full compliance of each coating system component with current and promulgated

federal, state, and local air pollution control regulations and requirements.

d. Material Safety Data Sheets (MSDS) for materials to be delivered to the job site,

including coating system materials, solvents, and abrasive blast media.

e. List of cleaning and thinner solutions allowed by the CSMs.

f. Storage requirements including temperature, humidity, and ventilation for

Coating System Materials as recommended by the CSMs.

g. CSM's detailed, written instructions for coating system treatment and graphic

details for coating system terminations in the structures to be coated including

pipe penetrations, metal embedments, gate frames, and other terminations to be

determined from the contract drawings. This information shall also include detail

treatment for coating system at joints in concrete.

h. The Contractor and CSA shall provide a minimum of five project references each

including contact name, address, and telephone number where similar coating

work has been performed by their companies in the past five years.

1.05 RESPONSIBILITIES OF THE CTR

A. General:

1. The Contractor shall retain or obtain the services of the CTR to be on site to perform

the Contractor and/or CSA application training and to routinely inspect and verify in

writing that the application personnel have successfully performed surface

preparation, filler/surface application, coating system application, and Quality Control

Inspection in accordance with this Section 09900 and to warrantable level of quality.

This must include checking the required degree of cleanliness, surface pH for

concrete substrates, surface profile of substrates, proper mixing of coating materials,

application (including checking the wet and dry film thickness of the coating

systems), proper cure of the coating systems, and proper treatment of coating

systems at terminations, transitions, and joints and cracks in substrates. Refer to

paragraph 1.05 Coating System Installation Training. for further details on these CTR




09900 - 9

requirements. This inspection is in addition to the inspection performed by the

Contractor in accordance with this Section 09900.

B. Coating System Installation Training:

1. Provide a minimum of 8 hours of classroom and off site training for application and

supervisory personnel (both the Contractor's and CSA’s). Provide training to a

minimum of two supervisory personnel from the CSA and one supervisor from the

Contractor. Alternatively, the CTR shall provide a written letter from the CSM stating

that the application personnel (listed by name) who shall perform coating work are

approved by the CSM without further or additional training.

2. One CTR can provide training for up to fourteen application personnel and three

supervisory personnel at one time. The training shall include the following as a

minimum:

a. A detailed explanation of mixing, application, curing, and termination details.

b. Hands-on demonstration of how to mix and apply the coating systems.

c. A detailed explanation of the ambient condition requirements (temperature and

humidity) and surface preparation requirements for application of the coating

system as well as a detailed explanation of re-coat times, cure times, and related

ambient condition requirements.

d. When training is performed, the CTR shall provide a written letter stating that

training was satisfactorily completed by the personnel listed by name in the

letter.

C. Coating System Inspection:

1. While on site to routinely inspect and verify, the CTR shall perform the following

activities to confirm acceptability and conformance with the specifications:

a. Inspect ambient conditions during various coating system installation at hold

points for conformance with the specified requirements.

b. Inspect the surface preparation of the substrates where the coating system will

terminate or will be applied for conformance to the specified application criteria.

c. Inspect preparation and application of coating detail treatment (for example,

terminations at joints, metal embedments in concrete, etc.).

d. Inspect application of the filler/surface materials for concrete and masonry

substrates.

e. Inspect application of the primers and finish coats including wet and dry film

thickness of the coatings.

f. Inspect coating systems for cure.

g. Review adhesion testing of the cured coating systems for conformance to

specified criteria.

h. Review coating system continuity testing for conformance to specified criteria.

i. Inspect and record representative localized repairs made to discontinuities

identified via continuity testing.

j. Conduct a final review of completed coating system installation for conformance

to the specifications.




09900 - 10

k. Prepare and submit a site visit report following each site visit that documents the

acceptability of the coating work in accordance with the CSM’s

Recommendations.

D. Final Report:

1. Upon completion of coating work for the project, the CTR shall prepare a final report.

That report shall summarize daily test data, observations, drawings, and photographs

in a report to be submitted in accordance with paragraph 2.02. Include substrate

conditions, ambient conditions, and application procedures, observed during the

CTR's site visits. Include a statement that the completed work was performed in

accordance with the requirements of this Section 09900 and the CSM’s

recommendations.

PART 2 PRODUCTS

2.01 MATERIALS

A. General:

1. Notwithstanding the listing of product names in this Section 09900, the Contractor

shall provide affidavits, signed and sealed by an officer of the CSM’s corporation,

attesting to full compliance of each coating system component with current and

promulgated federal, state, and local air pollution control regulations and

requirements. No coatings shall be applied to a surface until the specified affidavits

have been submitted and have been reviewed and accepted. Failure to comply with

this requirement shall be cause for rejection and removal of such materials from the

site.

2. The following list specifies the material requirements for coating systems. Coating

systems are categorized by generic name followed by an identifying abbreviation. If

an abbreviation has a suffix number, it is for identifying subgroups within the coating

system. Coating Systems E-5 and E-6 shall be NSF 61 certified.




09900 - 11

Material Requirements for Coating Systems: All of U.S. Except California

Coating System CSM First Coat(s) Finish Coat(s)

Epoxy Coatings

E-1 PPG PMC Amerlock 2/400 Series Amerlock 2/400 Series

Carboline Carboguard 890 Carboguard 890

International Paint/ICI

*

Devran 224 HS Devran 224

Sherwin Williams Macropoxy 646 Macropoxy 646

Tnemec Series V69 Series V69



International Paint/ICI Bar-Rust 236 Bar-Rust 236

Sherwin Williams Sea Guard 6000 Epoxy N11-400 Sea Guard 6000 Epoxy

N11-400

Tnemec Series V27 or V69 Series V69



International Paint/ICI Bar-Rust 236 Bar-Rust 236

Sherwin Williams Macropoxy 646 Macropoxy 646

Tnemec Series V69 Series V69

Specialty Epoxy Linings

EA-1 Carboline Plasite 4500S Plasite 4500S

Sauereisen Sewergard 210S Sewergard 210S

Tnemec Series 435 Series 435

Epoxy Polyurethane

Primer Coat(s) Intermediate Coat(s)

EU-1 PPG PMC Amercoat Amercoat 385 Amercoat 450H

Carboline Carbozinc 859 Carboguard 890 Carbothane 134 VOC

International Paint/ICI Cathacoat 313 Devran 233 or 224HS Devthane 379

Sherwin Williams Zinc Clad IV Macropoxy 646 Hi Solids Polyurethane

Tnemec Series 90-97 Series V69 Series 1075

Latex Acrylic

L-1 PPG PMC Amercoat 148 Amercoat 220

Carboline Carbocrylic 120 Carbocrylic 3359

International Paint/ICI UH Gripper 3210 Dulux Pro 1406

Sherwin Williams Loxon Acrylic Primer Sher Cryl HPA

Tnemec Series 1028 or 1029 Series 1028 or 1029

L-2 PPG PMC Amercoat 220 Amercoat 220




09900 - 12

Coating System CSM First Coat(s) Finish Coat(s)

Carboline Carbocrylic 120 Carbocrylic 3359

International Paint/ICI Prep and Prime Gripper Ultrahide 250-1406

Sherwin Williams Sher Cryl HPA Sher Cryl HPA

Tnemec Series 1028 or 1029 Series 1028 or 1029

Miscellaneous

M-1 Carboline Carbowrap Priming Paste Tape A, B, or C (temp.

dependent)

Denso Denso Paste Densyl Tape

Trenton Waxtape Primer #1 Wax Tape

M-2 Carboline Carbomastic 15 Carbomastic 15

International Paint/ICI Bar-Rust 231 (231K 9100) Bar-Rust 231 (231K

9100)

Sherwin Williams Epoxy Mastic Aluminum II Epoxy Mastic

Aluminum II

Tnemec Series 135 (1243) Series 135 (1243)

Penetrating Stain

CSM Primer Finish

S-1 Carboline Carbocrete Sealer WB Carbocrete Sealer WB

International Paint/ICI Groundworks Groundworks

Sherwin Williams H&C Acrylic Concrete Stain H&C Acrylic Concrete

Stain

Tnemec Series 617 Series 617

S-2 Tnemec N/A Series 636 Dur A Pell

20

Curecrete Chemical

Company

N/A Ashford Formula

S-3 Tnemec N/A Series V626 Dur A Pell

GS




09900 - 13

2.02 PRODUCT DATA

A. Prior to application of coatings, submit letter(s) from the CTR(s) identifying the

application personnel who have satisfactorily completed training as specified in

paragraph 09900-1.05 or a letter from the CSM stating that personnel who shall perform

the work are approved by the CSM without need for further or additional training.

B. Submit reports specified in paragraph 09900-1.02 C.10 and 09900-1.05 B.12 when the

work is underway.

C. Submit the Coating System Inspection Checklists, using Form 09900-A, for the coating

work.

D. CTR final report in accordance with paragraph 09900-1.05 C.

PART 3 EXECUTION

3.01 COATINGS

A. GENERAL:

1. Coating products shall not be used until the Construction Manager has accepted the

affidavits specified in paragraph 09900-1.04 and 2.01, the Construction Manager

has inspected the materials, and the CTR has trained the Contractor and CSA in the

surface preparation, mixing and application of each coating system.

B. SHOP AND FIELD COATS:

1. SHOP APPLIED PRIME COAT: Except as otherwise specified, prime coats may be

shop-applied or field-applied. Shop-applied primer shall be compatible with the

specified coating system and shall be applied at the minimum dry film thickness

recommended by the CSM. Data sheets identifying the shop primer used shall be

provided to the on-site coating application personnel. Adhesion tests shall be

performed on the shop primer as specified in paragraph 09900-3.01B.3. Damaged,

deteriorated and poorly applied shop coatings that do not meet the requirements of

this Section 09900 shall be removed and the surfaces recoated. If the shop primer

coat meets the requirements of this Section 09900, the field coating may consist of

touching up the shop prime coat and then applying the finish coats to achieve the

specified film thickness and continuity.

2. FIELD COATS: Field coats shall consist of one or more prime coats and one or more

finish coats to build up the coating to the specified dry film thickness. Unless

otherwise specified, finish coats shall not be applied until other work in the area is

complete and until previous coats have been inspected.

3. ADHESION CONFIRMATION: The Contractor shall perform an adhesion test after

proper cure in accordance with ASTM D3359 to demonstrate that (1) the shop

applied prime coat adheres to the substrate, and (2) the specified field coatings

adhere to the shop coat. Test results showing an adhesion rating of 5A on immersed

surfaces and 4A or better on other surfaces shall be considered acceptable for

coatings 5 mils or more in thickness (Method A). Test results showing an adhesion

rating of 5B on immersed surfaces and 4B or better on other surfaces shall be

considered acceptable for coating thicknesses less than 5 mils.




09900 - 14

C. APPLICATION LOCATION REQUIREMENTS:

1. EQUIPMENT, NONIMMERSED: Items of equipment, or parts of equipment that are

not immersed in service, shall be shop primed and then finish coated in the field

after installation with the specified or acceptable color. If the shop primer requires

topcoating within a specified period, the equipment shall be finish coated in the shop

and then touch-up painted after installation. If equipment removal and reinstallation

is required for the project, touch-up coating work shall be performed in the field

following installation.

2. EQUIPMENT, IMMERSED: Items of equipment, or parts and surfaces of equipment

that are immersed when in service, with the exception of pumps and valves, shall

have surface preparation and coating work performed in the field. Coating systems

applied to immersed equipment shall be pinhole free.

3. STEEL WATER TANKS: The interior surfaces of steel water tanks or reservoirs shall

have surface preparation and coating work performed in the field.

D. Erect and maintain protective enclosures as stipulated per SSPC-Guide 6 Guide for

Containing Debris Generated During Paint Removal Operations.

3.02 PREPARATION

A. GENERAL:

1. Surface preparations for each type of surface shall be in accordance with the specific

requirements of each coating specification sheet (COATSPEC) and the following. In

the event of a conflict, the COATSPEC sheets shall take precedence.

2. Surfaces to be coated shall be clean and dry. Before applying coating or surface

treatments, oil, grease, dirt, rust, loose mill scale, old weathered coatings, and other

foreign substances shall be removed. Oil and grease shall be removed before

mechanical cleaning is started. Where mechanical cleaning is accomplished by blast

cleaning, the abrasive used shall be washed, graded and free from contaminants

that might interfere with the adhesion of the coatings. The air used for blast cleaning

shall be sufficiently free of oil and moisture so as not to cause detrimental

contamination of the surfaces to be coated.

3. Where deemed necessary by the Owner’s representative, a NACE International

certified coatings inspector, provided by the Owner, will inspect and approve surfaces

to be coated before application of a coating. Surface defects identified by the

inspector shall be corrected by the Contractor at no additional cost to the Owner.

4. Cleaning and painting shall be scheduled so that dust and spray from the cleaning

process shall not fall on wet, newly coated surfaces. Hardware, hardware

accessories, nameplates, data tags, machined surfaces, sprinkler heads, electrical

fixtures, and similar uncoated items which are in contact with coated surfaces shall

be removed or masked prior to surface preparation and painting operations.

Following completion of coating, removed items shall be reinstalled. Equipment

adjacent to walls shall be disconnected and moved to permit cleaning and painting of

equipment and walls and, following painting, shall be replaced and reconnected.




09900 - 15

B. BLAST CLEANING:

1. When abrasive blast cleaning is required to achieve the specified surface preparation

the following requirements for blast cleaning materials and equipment shall be met:

a. Used or spent blast abrasive shall not be reused on this project.

b. The compressed air used for blast cleaning shall be filtered and shall contain no

condensed water and no oil. Moisture traps shall be cleaned at least once every

four hours or more frequently as required to prevent moisture from entering the

supply air to the abrasive blasting equipment.

c. Oil separators shall be installed just downstream of compressor discharge valves

and at the discharge of the blast pot discharges. These shall be checked on the

same frequency as the moisture traps as defined in item 2 above.

d. Regulators, gauges, filters, and separators shall be in use on compressor air lines

to blasting nozzles times during this work.

e. An air dryer or desiccant filter drying unit shall be installed which dries the

compressed air prior to blast pot connections. This dryer shall be used and

maintained for the duration of surface preparation work.

f. The abrasive blast nozzles used shall be of the venturi or other high velocity type

supplied with a minimum of 100 psig air pressure and sufficient volume to obtain

the blast cleaning production rates and cleanliness/specified.

g. The Contractor shall provide ventilation for airborne particulate evacuation

(meeting pertinent safety standards) to optimize visibility for both blast cleaning

and inspection of the substrate during surface preparation work.

h. If, between final surface preparation work and coating system application,

contamination of prepared and cleaned metallic substrates occurs, or if the

prepared substrates' appearance darkens or changes color, recleaning by water

blasting, reblasting and abrasive blast cleaning shall be required until the

specified degree of cleanliness is reclaimed.

i. The Contractor is responsible for dust control and for protection of mechanical,

electrical, and other equipment adjacent to and surrounding the work area.

C. SOLVENT CLEANING:

1. Any solvent wash, solvent wipe, or cleaner used, including but not limited to those

used for surface preparation in accordance with SSPC SP-1 Solvent Cleaning and

shall be of the emulsifying type which emits no more than 340 g/l VOCs for AIM

regions, 250 g/l for CARB regions and 100 g/l for SCAQMD regions, contains no

phosphates, is biodegradable, removes no zinc, and is compatible with the specified

primer.

2. Clean white cloths and clean fluids shall be used in solvent cleaning.

D. METALLIC SURFACES:

1. Metallic surfaces shall be prepared in accordance with applicable portions of surface

preparation specifications of the Society for Protective Coatings (SSPC) specified for

each coating system. See Coat Spec for each coating system in this Section 09900.

The profile depth of the surface to be coated shall be in accordance with the

COATSPEC requirements in this Section measured by Method C of ASTM D4417.

Blast particle size shall be selected by the Contractor to produce the specified




09900 - 16

surface profile. The solvent in solvent cleaning operations shall be as recommended

by the CSM.

2. Preparation of metallic surfaces shall be based upon comparison with SSPC-VIS1-89

(ASTM D2200), and as described in the Coat Spec for each coating system. If dry

abrasive blast cleaning is selected and to facilitate inspection, the Contractor shall,

on the first day of cleaning operations, abrasive blast metal panels to the standards

specified. Plates shall measure a minimum of 8-1/2 inches by 11 inches. Panels

meeting the requirements of the specifications shall be initialed by the Contractor

and the Construction Manager and coated with a clear non-yellowing finish. One of

these panels shall be prepared for each type of abrasive blasting and shall be used

as the comparison standard throughout the project.

3. Blast cleaning requirements for steel, ductile iron and stainless steel substrates are

as follows:

a. Steel piping shall be prepared in accordance with SSPC SP-6 (Commercial Blast

Cleaning) and primed before installation. Ductile iron piping surfaces including

fittings shall be prepared in accordance with NAPF 500-03, NAPF 500-03-04, and

NAPF 500-03-05.

b. Stainless steel surfaces shall be abrasive blast cleaned to leave a clean uniform

appearance with a minimum surface profile of 1.5 to 2.5 mils that is uniform.

c. Remove traces of grit, dust, dirt, rust scale, friable material, loose corrosion

products or embedded abrasive from substrate by vacuum cleaning prior to

coating application.

d. Care must be taken to prevent contamination of the surface after blasting from

worker’s fingerprints, deleterious substances on workers’ clothing, or from

atmospheric conditions.

e. Ambient environmental conditions in the enclosure must be constantly monitored

and maintained to ensure the degree of cleanliness is held and no “rust back”

occurs prior to coating material application.

E. CONCRETE SURFACES:

1. Inspection of concrete surfaces prior to surface preparation and surface preparation

of concrete surfaces shall be performed in accordance with SSPC-SP13 (also called

NACE 6).

2. Prepare substrate cracks, areas requiring resurfacing and perform detail treatment

including but not limited to, terminating edges, per CSM recommendations. This

shall precede surface preparation for degree of cleanliness and profile.

3. The surface profile for prepared concrete surfaces to be coated shall be evaluated by

comparing the profile of the prepared concrete with the profile of graded abrasive

paper, as described in ANSI B74.18 or by comparing the profile with the ICRI 03732

(surface profile replicas). Surface profile requirements shall be in accordance with

the Coat Spec requirements and the CSM’s recommendations.

4. Surface cleanliness of prepared concrete substrates shall be inspected after

cleaning, preparation, and/or drying, but prior to making repairs or applying a coat in

the coating system. If concrete surfaces are repaired, they shall be reinspected for

surface cleanliness prior to application of the coating system.

5. Surface preparation of concrete substrates shall be accomplished using methods

such as dry abrasive blast cleaning, high, or ultra high-pressure water blast cleaning




09900 - 17

in accordance with SSPC-SP-13. The selected cleaning method shall produce the

requirements set forth below.

a. A clean substrate that is free of calcium sulfate, loose coarse or fine aggregate,

laitance, loose hydrated cement paste, and otherwise deleterious substances

shall be achieved. Blast cleaning and other means necessary shall be used to

open up air voids or bugholes to expose their complete perimeter. Leaving

shelled over, hidden air voids beneath the exposed concrete surface is not

acceptable. Concrete substrate must be dry prior to the application of

filler/surface or coating system materials.

b. Acceptable surface preparation must produce a concrete surface with a

minimum pH of 8.0 to be confirmed by surface pH testing. If after surface

preparation, the surface pH remains below 8.0, perform additional water

blasting, cleaning, or abrasive blast cleaning until additional pH testing indicates

an acceptable pH level.

c. Following inspection by the Contractor of the concrete surface preparation,

thoroughly vacuum clean concrete surfaces to be coated to remove loose dirt,

and spent abrasive (if dry blast cleaning is used) leaving a dust free, sound

concrete substrate. Debris produced by blast cleaning shall be removed from the

structures to be coated and disposed of legally off site by the Contractor.

6. Should abrasive blast cleaning or high or ultrahigh pressure water blasting not

remove degraded concrete, chipping or other abrading tools shall be used to remove

the deteriorated concrete until a sound, clean substrate is achieved which is free of

calcium sulfate, loose coarse or fine aggregate, laitance, loose hydrated cement

paste, and otherwise deleterious substances. Concrete substrates must be dry prior

to the application of filler/surfacers or coating system materials.

7. Surface cleanliness of prepared concrete substrates shall be inspected after

cleaning, preparation, and/or drying, but prior to application of coating materials. If

concrete surfaces are repaired, they shall be reinspected for surface cleanliness and

required surface profile prior to application of the coating system.

8. Moisture content of concrete to be coated shall be tested in accordance with ASTM

D4263, Standard Test Method for Indicating Moisture in Concrete by the Plastic

Sheet Method and ASTM F 1869, Standard Test Method for Measuring Moisture

Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride. The

ASTM D4263 plastic sheet test shall be conducted at least once for every 500 sq. ft.

of surface area to be coated. The presence of any moisture on plastic sheet

following test period constitutes a non-acceptable test. For concrete surfaces to be

coated which are on the negative or back side of concrete walls or structures

exposed to soils (back filled) or immersed and waterproofed in accordance with

Section 07100, perform calcium chloride tests in accordance with ASTM F-1869

once for each 500 sq. ft. of surface area to be coated. Comply with CSM’s written

recommendations regarding acceptance/non-acceptance of moisture vapor

emissions.

A. Masonry Surfaces:

1. Prepare masonry surfaces such as Concrete Masonry Units (CMU) to remove chalk,

loose dirt, dried mortar splatter, dust, peeling, or loose existing coatings, or otherwise

deleterious substances to leave a clean, sound substrate.




09900 - 18

2. Be certain masonry surfaces are dry prior to coating application. If pressure washing

or low-pressure water blast cleaning is used for preparation, allow the masonry to dry

for at least 5 days under dry weather conditions or when the minimum ambient

temperature is 70 degrees F prior to coating application work.

B. Fiberglass Reinforced Plastic (FRP) Surfaces:

1. Prepare FRP surfaces by sanding to establish uniform surface roughness and to

remove gloss from the resin in the FRP. Next, vacuum clean to remove loose FRP

dust, dirt, and other materials. Next, solvent clean using clean white rags and allow

solvent to evaporate completely before application of coating materials.

3.03 APPLICATION

A. Workmanship:

1. Coated surfaces shall be free from runs, drips, ridges, waves, laps, and brush marks.

Coats shall be applied to produce an even film of uniform thickness completely

coating corners and crevices.

2. The Contractor's equipment shall be designed for application of the materials

specified. Compressors shall have suitable traps and filters to remove water and oils

from the air. A paper blotter test shall be performed by the Contractor when

requested by the Construction Manager to determine if the air is sufficiently free of

oil and moisture so as not to produce deteriorating effects on the coating system.

The amount of oil and moisture in spray air shall be less than the amount

recommended by the CSM. Spray equipment shall be equipped with mechanical

agitators, pressure gages, and pressure regulators, and spray nozzles of the proper

sizes.

3. Each coat of coating material shall be applied evenly and sharply cut to line. Care

shall be exercised to avoid overspraying or spattering paint on surfaces not to be

coated. Glass, hardware, floors, roofs, and other adjacent areas and installations

shall be protected by taping, drop cloths, or other suitable measures.

4. Coating applications method shall be conventional or airless spray, brush or roller, or

trowel as recommended by CSM.

5. Allow each coat to cure or dry thoroughly, according to CSM’s printed instructions,

prior to recoating.

6. Vary color for each successive coat for coating systems when possible.

7. When coating complex steel shapes, prior to overall coating system application,

stripe coat welds, edges of structural steel shapes, metal cut-outs, pits in steel

surfaces, or rough surfaces with the primer coat. This involves applying a separate

coat using brushes or rollers to ensure proper coverage. Stripe coat via spray

application is not permitted.

B. Coating Properties, Mixing and Thinning:

1. Coatings, when applied, shall provide a satisfactory film and smooth even surface.

Glossy undercoats shall be lightly sanded to provide a surface suitable for the proper

application and adhesion of subsequent coats. Coating materials shall be thoroughly

stirred, strained, and kept at a uniform consistency during application. Coatings

consisting of two or more components shall be mixed in accordance with the CSM’s

instructions. Where necessary to suit the conditions of the surface, temperature,




09900 - 19

weather and method of application, the coating may be thinned as recommended by

the CSM immediately prior to use. The volatile organic content (VOC) of the coating as

applied shall comply with prevailing air pollution control regulations. Unless otherwise

specified, coatings shall not be reduced more than necessary to obtain the proper

application characteristics. Thinner shall be as recommended by the CSM.

C. Atmospheric Conditions:

1. Coatings shall be applied only to surfaces that are dry, and only under conditions of

evaporation rather than condensation. Coatings systems shall not be applied during

rainy, misty weather, or to surfaces upon which there is frost or moisture

condensation. During damp weather, when the temperature of the surface to be

coated is within 10 degrees F of the dew point, forced dehumidification equipment

may be used to maintain a temperature of minimum 40 degrees F and 10 degrees F

above the dew point for the surfaces to be coated, the coated surface, and the

atmosphere in contact with the surface. These conditions shall be maintained for a

period of at least 8 hours or as recommended by the CSM. Where conditions causing

condensation are severe, dehumidification equipment, fans, and/or heaters shall be

used inside enclosed areas to maintain the required atmospheric and surface

temperature requirements for proper coating application and cure.

D. Concrete Substrate Temperatures and Detail Treatment:

1. When the surface temperatures of the concrete substrates to be coated are rising or

when these substrates are in direct sunlight, outgassing of air from the concrete may

result in bubbling, pinhole formations, and/or blistering in the coating system. The

application of the filler/surface and the coating system will only be allowed during

periods of falling temperature. This will require that application of the filler/surface

and coating system shall only occur during the cooler evening hours. Contractor shall

include any cost for working outside of normal hours in the bid.

2. Should bubbles, pinholes, or discontinuities form in the applied coating system

material, they shall be repaired as recommended by the CSM. Should pinholes

develop in the filler/surfacer material or in the first coat of the coating material, the

pinholes shall be repaired in accordance with the CSM’s recommendations prior to

application of the next coat of material. Whenever pinholes occur, the air void behind

or beneath the pinhole shall be opened up completely and then completely filled with

the specified filler/surfacer material. Next, the coated area around the pinhole repair

shall be abraded and the coating reapplied over that area.

3. Perform application detail work per CSM’s current written recommendations and/or

drawings.

E. Protection of Coated Surfaces:

1. Items that have been coated shall not be handled, worked on, or otherwise

disturbed, until the coating is completely dry and hard. After delivery at the site, and

upon permanent erection or installation, shop-coated metalwork shall be recoated or

retouched with specified coating when it is necessary to maintain the integrity of the

film.

F. Method of Coating Application:

1. Where two or more coats are required, alternate coats shall contain sufficient

compatible color additive to act as indicator of coverage, or the alternate coats shall




09900 - 20

be of contrasting colors. Color additives shall not contain lead, or lead compounds,

which may be destroyed or affected by hydrogen sulfide or other corrosive gas,

and/or chromium.

2. Mechanical equipment, on which the equipment manufacturer's coating is

acceptable, shall be touch-up primed and coated with two coats of the specified

coating system to match the color scheduled. Electrical and instrumentation

equipment specified in Divisions 26 and 40 shall be coated as specified in

paragraph 3.03 Electrical and Instrumentation Equipment and Materials.

3. Coatings shall not be applied to a surface until it has been prepared as specified. The

primer or first coat shall be applied by brush to ferrous surfaces that are not blast-

cleaned. Coats for blast-cleaned ferrous surfaces and subsequent coats for nonblast-

cleaned ferrous surfaces may be either brush or spray applied. After the prime coat is

dry, pinholes and holidays shall be marked, repaired in accordance with CSM's

recommendations and retested before succeeding coats are applied. Unless

otherwise specified, coats for concrete and masonry shall be brushed, rolled, or

troweled.

G. Film Thickness and Continuity:

1. WFT of the first coat of the coating system and subsequent coats shall be verified by

the Contractor, following application of each coat.

2. The surface area covered per gallon of coating for various types of surfaces shall not

exceed those recommended by the CSM. The first coat, referred to as the prime coat,

on metal surfaces refers to the first full paint coat and not to solvent wash, grease

emulsifiers or other pretreatment applications. Coatings shall be applied to the

thickness specified, and in accordance with these specifications. Unless otherwise

specified, the average total thickness (dry) of a completed protective coating system

on exposed metal surfaces shall be not less than 1.25 mils per coat. The minimum

thickness at any point shall not deviate more than 25 percent from the required

average. Unless otherwise specified, no less than two coats shall be applied.

3. In testing for continuity of coating about welds, projections (such as bolts and nuts),

and crevices, the Construction Manager shall determine the minimum conductivity

for smooth areas of like coating where the dry-mil thickness has been accepted. This

conductivity shall be the minimum required for these rough or irregular areas.

Pinholes and holidays shall be recoated to the required coverage.

4. The ability to obtain specified film thickness is generally compromised when brush or

roller application methods are used and, therefore, more coats may need to be

applied to achieve the specified dry film thickness.

5. For concrete substrates, the Contractor shall apply a complete skim coat of the

specified filler/surfacer material over the entire substrate prior to application of the

coating system. This material shall be applied such that all open air voids and

bugholes in the concrete substrate are completely filled prior to coating application.

H. Special Requirements:

1. Before erection, the Contractor shall apply all but the final finish coat to interior

surfaces of roof plates, roof rafters and supports, pipe hangers, piping in contact with

hangers, and contact surfaces that are inaccessible after assembly. The final coat

shall be applied after erection. Structural friction connections and high tensile bolts

and nuts shall be coated after erection. Areas damaged during erection shall be




09900 - 21

hand-cleaned or power-tool cleaned and recoated with primer coat prior to the

application of subsequent coats. Touch-up of surfaces shall be performed after

installation. Surfaces to be coated shall be clean and dry at the time of application.

Except for those to be filled with grout, the underside of equipment bases and

supports that have not been galvanized shall be coated with at least two coats of

primer specified for system E-2 prior to setting the equipment in place. Provide

coating system terminations at leading edges and transitions to other substrates in

accordance with the CSM’s recommendations or detail drawings.

I. Electrical and Instrumentation Equipment and Materials:

1. Electrical and instrumentation equipment and materials shall be coated by the

equipment manufacturer as specified below.

a. Finish: Electrical equipment shall be treated with zinc phosphate, bonderized or

otherwise given a rust-preventive treatment. Equipment shall be primed, coated

with enamel, and baked. Minimum dry film thickness shall be 3 mils.

1) Unless otherwise specified, instrumentation panels shall be coated with

system E-1 for indoor mounting and system EU-1 for outdoor mounting.

2) Before final acceptance, the Contractor shall touch up scratches on

equipment with identical color coating. Finish shall be smooth, free of runs,

and match existing finish. Prior to touching up scratches, Contractor shall fill

them with an appropriate filler material approved by the CSM.

b. Color: Exterior color of electrical equipment shall be FS 26463 (ANSI/NSF 61)

light gray. Interior shall be painted FS 27880 white. Nonmetallic electrical

enclosures and equipment shall be the equipment manufacturer's standard grey

color.

1) Exterior color of instrumentation panels and cabinets mounted indoors shall

be FS 26463 light gray; unless otherwise specified, exterior color for cabinets

mounted outdoors shall be FS 27722, white. Cabinet interiors shall be FS

27880, white.

J. Soluble Salt Contamination of Metallic Substrates:

1. Contractor shall test in accordance with SSPC-TU-4 metallic substrates to be coated

that have been exposed to seawater or coastal air or to industrial fallout of

particulate or other sources of soluble chlorides (such as wastewater exposure). If

testing indicates detrimental levels of soluble salts, those in excess of 25 ppm, the

Contractor shall clean and prepare these surfaces to remove the soluble salts.

3.04 CLEANUP

A. General:

1. Upon completion of coating, the Contractor shall remove surplus materials, protective

coverings, and accumulated rubbish, and thoroughly clean surfaces and repair

overspray or other coating-related damage.

3.05 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC)

1. Coating systems for different types of surfaces and general service conditions for

which these systems are normally applied are specified on the following COATSPEC

sheets. Surfaces shall be coated in accordance with the COATSPEC to the system




09900 - 22

thickness specified. Coating systems shall be as specified in paragraph 3.06. In case

of conflict between the schedule and the COATSPECS, the requirements of the

schedule shall prevail.

2. Coating Specification Sheets included in Table A are included this paragraph 3.05.

Table A Coating Specification Sheets

Coating System ID Coating Material Surface Service Condition

E-1 Epoxy Metal Interior; exterior, covered, not exposed to direct

sunlight, non-corrosive exposure.

E-2 Epoxy Metal Immersed, nonpotable; non-immersed,

moderately corrosive environment, color

required.

E-4 Epoxy Concrete, masonry, plaster,

gypsum board

Interior

EA-1 Blended Amine Cured

Epoxy

Metal Immersed, nonpotable; non-immersed, corrosive

environment, color not required especially for

headspace environments that are corrosive due

to biogenic sulfide corrosion.

EU-1 Zinc-epoxy-polyurethane

system

Ferrous Metal Exterior, exposed to direct sunlight, moderately

corrosive non-immersed.

L-1 Latex Concrete, masonry, plaster,

gypsum board

Interior and Exterior including existing exterior

coated concrete.

L-2 Latex PVC and CPVC pipe Exterior, direct sunlight exposure.

M-1 Petrolatum based mastic

or wax based wrapping

tapes

Metal Below grade (buried) or where little to no surface

preparation can be performed on piping or

structural steel.

M-2 Epoxy mastic or equal Ferrous Metal Interior, corrosive environment, confined

enclosures, where minimal surface preparation is

possible.

S-1 Penetrating acrylic stain,

color required

Concrete Non-immersed, exposure to moisture and

sunlight.

S-2 Silane/Siloxane or

Blended Sealer

Concrete Floors Wet, non-immersed, non-corrosive. Interior or

exterior for waterproofing.

S-3 RTV Silicone Rubber

Based Sealer

Concrete or Masonry Walls Exterior or Interior – Weathering Exposure, Non-

Corrosive.




09900 - 23

Coating System Specification Sheets (COATSPEC)

A. Coating System Identification: E-1

1. Coating Material: Epoxy

2. Surface: Metal

3. Service Condition: Interior; exterior, covered, not exposed to direct sunlight, non-corrosive exposure.

4. Surface Preparation:

a. General: Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) to achieve a uniform surface profile of 2.0 to 2.5 mils and spot primed with the primer specified. Shop epoxy primed surfaces shall require light abrasive and vacuum cleaning blasting prior to receiving finish coats.

b. Ferrous Metal: Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning) to achieve a uniform, surface profile of 2.0 to 2.5 mils.

Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC SP-1 (Solvent Cleaning). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) (to achieve the 2.0- to 2.5-mil surface profile) and spot primed with the specified primer. For ductile iron surfaces, refer to the requirements in paragraph 3.02 Metallic Surfaces.

c. Nonferrous and

Galvanized Metal: Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning) to achieve uniform, minimum surface profile 1.0 to 1.5 mils.

5. Application: Field

a. General: Prime coat may be thinned and applied as recommended by the CSM, provided the coating as applied complies with prevailing air pollution control regulations.

b. Ferrous Metal: Prime coats shall be an epoxy primer compatible with the specified finish coats and applied in accordance with the written instructions of the CSM.

c. Nonferrous and

Galvanized Metal: Nonferrous and galvanized metal shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning).

6. System Thickness: 10 mils dry film.

7. Coatings:

a. Primer: One coat at CSM's recommended dry film thickness.

b. Finish: One or more coats at CSM's recommended dry film thickness per coat to achieve the specified system thickness.

B. Coating System Identification: E-1-G


2. Surface: Galvanized Steel

3. Service Condition: Interior; exterior, covered, non-corrosive exposure. Do not use in immersion service.


a. General: Damaged galvanized steel areas with exposed ferrous metal and/or rusted shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) or Power Tool Cleaned to Bare Metal in accordance with SSPC-SP-11 to achieve a uniform




09900 - 24

Coating System Specification Sheets (COATSPEC) 1.0- to 1.5-milprofile and spot primed with the primer specified.

b. Galvanized Metal: Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning) impart a 1- to 2-milprofile to the galvanized steel surfaces. Where this cannot be performed, prepare by abrading in accordance with SSPC-SP-3, Power Tool Cleaning to impart a 1.0- to 1.5-mil profile uniformly to the galvanized steel surfaces.



b. Galvanized Metal: Nonferrous and galvanized metal shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning).

6. System Thickness: 5 to 8 mils dry film.

7. Coatings:


b. Finish: One or more coats at CSM's recommended dry film thickness per coat to the specified system thickness.

If the coated galvanized steel is to be exposed to ultraviolet light, apply one polyurethane top coat from coating system EU-1 over the second coat of the two epoxy coats specified.

C. Coating System Identification: E-2


2. Surface: Metal

3. Service Condition: Immersed, nonpotable; non-immersed, moderately corrosive environment, color required.


a. Ferrous Metal: Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning) to achieve a uniform surface profile of 2.0 to 2.5 mils.

Damaged shop coating shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and vacuum cleaning and spot primed with the primer specified. Shop epoxy primed surfaces shall require light abrasive blasting or abrading prior to receiving finish coats if the maximum recoat time for the primer has been exceeded. This cleaning must produce a uniform 1.0- to 1.5-mil profile in the intact shop primer. For ductile iron surfaces, refer to the requirements in paragraph 3.02 Metallic Surfaces.

b. Nonferrous and

Galvanized Metal: Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning) to achieve a uniform surface profile of 1.0 to 1.5 mils. Galvanized steel with this E-2 coating system shall not be used in immersion service in wastewater.



b. Ferrous Metal: Prime coat shall be an epoxy primer compatible with the specified finish coats.

c. Nonferrous and

Galvanized Metal: Nonferrous and galvanized metal, non-immersed, shall be coated prior to the application of the prime coat with a grease emulsifying agent in accordance with the CSM's written instructions. Nonferrous metal to be immersed shall not be




09900 - 25

Coating System Specification Sheets (COATSPEC) painted. Galvanized metal shall not be immersed even if it is painted.


7. Coatings:


b. Finish: Two or more coats at CSM's recommended dry film thickness per coat to the specified system thickness.

D. Coating System Identification: E-4


2. Surfaces: Concrete, masonry, plaster, gypsum board.

3. Service Condition: Interior


a. Concrete: Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the CSM. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Loose concrete, form oils, surface hardeners, curing compounds and laitance shall be removed from surfaces, and voids and cracks shall be repaired as specified in Section 03300. Surface preparation shall produce a concrete surface profile of CSP-2 in accordance with ICRI 03732. After cleaning, air voids or bugholes in the concrete shall be filled with a surfacer or block filler compatible with the specified primer and finish coats.

b. Masonry: Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repointed. Loose or splattered mortar shall be removed by scrapping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, exterior masonry surfaces shall be sealed or filled with a sealer or block filler compatible with the specified primer.

c. Plaster: Plaster surfaces shall be dry, clean, and free from grit, loose plaster, and surface irregularities. Cracks and holes shall be repaired with acceptable patching materials, keyed to existing surfaces, and sandpapered smooth. Surfaces shall be cleaned with clean water by washing and scrubbing to remove foreign and deleterious substances.


a. General: Block Filler shall be multiple component epoxy block filler or an acrylic based or waterborne epoxy based block filler and shall dry a minimum of 48 hours prior to primer application or as required by the CSM.

Prime coat shall be thinned and applied as recommended by CSM, provided the coating as applied complies with prevailing air pollution control regulations.

Drying time between coats shall be as recommended by CSM.

6. System Thickness: 10 mils dry film, excluding block filler and sealer.

7. Coatings:






09900 - 26


E. Coating System Identification: EA-1

1. Coating Material: Blended Amine Cured Epoxy

2. Surface: Metal

3. Service Condition: Immersed, nonpotable; non-immersed, corrosive environment, color not required especially for headspace environments that are corrosive due to biogenic sulfide corrosion.


a. Ferrous Metal: Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning) to achieve a uniform surface profile of 3.0 to 3.5 mils. Blast Cleaning shall produce a minimum surface profile of 3.0 mils.

Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-11 (Power Tool Cleaning to Bare Metal). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot primed with the primer specified. Shop epoxy primed surfaces shall require light abrasive blasting and blow down cleaning prior to receiving finish coats. Cast or ductile iron surfaces to be coated shall be abrasive blast cleaned to a clean, gray uniform metal appearance free of variations in color and loose materials. Ductile iron surfaces shall be prepared in accordance with paragraph 3.02 Metallic Surfaces.

b. Nonferrous and

Galvanized Metal: Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning) to achieve a uniform surface profile of 2.0 to 2.5 mils. Galvanized metal should generally not be used in these environments.



Drying time between coats shall be as specified by the CSM for the site conditions. If the maximum recoat time is exceeded, surface preparation shall require solvent washing, light abrasive blasting, or other procedures per CSM's instructions.

b. Ferrous Metal: If shop priming is required or field priming is necessary, the prime coat shall be an epoxy primer compatible with the specified coating system. Generally, the EA-1 coating system is self-priming and does not require a primer unless there is a special reason to prime the steel to hold the blast cleaning from rusting back.

6. System Thickness: 30 to 40 mils dry film.

7. Coatings:

a. Primer: One coat at CSM's recommended dry film thickness only if required by special circumstances.


c. Testing: Holiday detection shall be performed over 100% of the coated surface area to identify any holidays or pinholes that must be repaired.

d. Pinhole and Holiday

Repair Procedure: Pinholes and holidays identified by Holiday Detection shall be repaired as follows: • Using a pencil grinder, remove a ½-inch diameter area of the coating system

material back to the ferrous metal substrate. The metal must be shiny • Aggressively sand or abrade the intact coating system surface 2 inches

around the complete periphery of the ½-inch diameter removal area to produce a uniform 6 to 8 mils profile

• Vacuum clean the prepared area to remove all dust and dirt to achieve a




09900 - 27

Coating System Specification Sheets (COATSPEC) clean, sound surface. Tape the peripheral area to prevent coating application onto unprepared surfaces

• Brush apply one coat of the finish coating material. Following proper recoat cure time, apply additional coats of the finish coating system to achieve 60 mils DFT at the coating removal area and feather the coating onto the roughened coated surfaces to form a neat repair outline

F. Coating System Identification: EU-1

1. Coating Material: Zinc-Epoxy-Polyurethane System

2. Surface: Ferrous Metal

3. Service Condition: Exterior, exposed to direct sunlight, moderately corrosive, non-immersed.


a. General: Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-3 (Power Tool Cleaning) and recoated with the primer specified.

b. Ferrous Metal: Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning) 2.5 – 3.0. Ductile iron surfaces to be coated shall be abrasive blast cleaned in accordance with paragraph 3.02 Metallic Surfaces.

Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC-SP-11 (Power Tool Cleaning to Bare Metal). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) and spot primed with the specified primer.

c. Galvanized Metal: Damaged galvanized steel areas with exposed ferrous metal and/or rusted shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) or Power Tool Cleaned to Bare Metal in accordance with SSPC-SP-11 to achieve a uniform 1.0- to 1.5-mil profile and spot primed with the primer specified.

Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning) to impart a 1.0- to 2.0-mil profile to the galvanized steel surfaces. Where this cannot be performed, prepare by abrading in accordance with SSPC-SP-3, Power Tool Cleaning to impart a 1.0- to 1.5-mil profile uniformly to the galvanized steel surfaces.

For EU-1 over galvanized steel, delete the zinc rich primer.



b. Ferrous Metal: Prime coats shall be a zinc rich epoxy or polyurethane primer compatible for use with urethane finish coats and applied in accordance with written instructions of the CSM or in the case of CARB or SCAQMD applications, prime with specified primer that is not zinc rich. In these cases, only a two-coat system is applied.

6. System Thickness: 3 to 4 mils of zinc rich primer, one intermediate or primer epoxy coat at 5 to 6 mils and one finish coat of polyurethane at 2 to 3 mils DFT.

7. Coatings:


b. Intermediate: One coat at CSM’s recommended dry film thickness.

c. Finish: One coat at CSM's recommended dry film thickness per coat to meet the specified




09900 - 28

Coating System Specification Sheets (COATSPEC) system thickness.

G. Coating System Identification: L-1

1. Coating Material: Latex

2. Surfaces: Concrete, masonry, plaster, gypsum board.

3. Service Condition: Interior and exterior including existing exterior coated concrete.


a. Concrete: Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the CSM. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Loose concrete and laitance shall be removed from surfaces, and voids and cracks shall be repaired as specified in Section 03300.

b. Existing Coated

Concrete: Remove all loose coating down to a sound substrate or intact, well-adhered existing coating by scraping or other means. Then, abrade all surfaces to achieve a 0.5- to 1.5-mil uniform profile and vacuum clean to remove all loose dirt, paint chips, and dirt.

c. Masonry: Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repointed. Loose or splattered mortar shall be removed by scraping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, masonry surfaces shall be filled with block filler compatible with the specified primer.

d. Plaster: Plaster surfaces shall be dry, clean, and free from grit, loose plaster, and surface irregularities. Cracks and holes shall be repaired with acceptable patching materials, keyed to existing surfaces, and sandpapered smooth. Surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. After cleaning, surfaces shall be sealed with a compatible sealer.

e. Gypsum Wallboard: Tape joints and spackled nail heads shall be sanded smooth and dusted. Seal with PVA sealer for interior uses only.


a. General: Sealer or filler shall dry a minimum of 48 hours prior to primer application.

Drying time between coats shall be as recommended by CSM.


7. Coatings:


b. Finish: Two or more coats at CSM's recommended dry film thickness per coat to the specified system thickness.

H. Coating System Identification: L-2

1. Coating Material: Latex

2. Surface: PVC and CPVC pipe.

3. Service Condition: Exterior, direct sunlight exposure.

4. Surface Preparation: Plastic pipe shall be cleaned with solvent compatible with the specified primer and sanded to roughen surfaces to achieve a uniform surface profile of 1.0 to 1.5 mils. Vacuum clean after sanding to remove all loose dust, plastic particles, and dirt.




09900 - 29




7. Coatings:



I. Coating System Identification: M-1

1. Coating Material: Petrolatum based mastic or wax based wrapping tapes.

2. Surfaces: Metal

3. Service Condition: Below grade (buried) or where little to no surface preparation can be performed on piping or structural steel.

4. Surface Preparation: Remove loose scale, rust, dirt, excessive moisture, or frost from the surface in accordance with SSPC SP-2 (Hand Tool Cleaning).

5. Application: All surfaces shall be hand rubbed or brushed with a priming paste recommended by the CSM. Sharp projections such as threads, irregular contours, or badly pitted areas shall receive a liberal amount of priming paste to ensure maximum protection of metal throughout.

On irregular shaped surfaces, i.e., nuts, bolts, flanges, valves, etc., the Contractor shall use either of the following systems recommended by the CSM.

A. Apply recommended mastic by hand in sufficient quantity to build an even contour over entire surface. The Contractor shall pay particular attention to ensure that folds and air pockets within the mastic layer are thoroughly pressed out prior to subsequent application of tape.

OR:

B. An extra layer of tape shall be cut and carefully molded around sharp projections, nuts, bolts, etc., before final application of tape, in order to meet specified system thickness.

Tape shall be spirally wrapped with a 55 percent overlap and sufficient tension and pressure to provide continuous adhesion without stretching the tape. Edges of tape must be continuously smoothed and sealed by hand during wrapping. On vertical application, contractor shall begin at bottom and proceed upward creating a weatherboard overlap.

6. System Thickness: Smooth contours shall have a minimum thickness of 50 mils while nuts, bolts, and sharp projections shall be 100 mils.

7. Tape: Number and types of tape wraps shall be in accordance with the CSM's written instructions.

J. Coating System Identification: M-2

1. Coating Material: Epoxy mastic or equal

2. Surface: Ferrous Metal

3. Service Condition: Interior, corrosive environment, confined enclosures, where minimal surface preparation is possible.


a. Ferrous Metal: All uncoated ferrous metal surfaces shall be prepared in accordance with SSPC SP-3 (Power Tool Cleaning), or SSPC-SP-11 (Power to Cleaning to Bare Metal) prior




09900 - 30

Coating System Specification Sheets (COATSPEC) to assembly. Surface preparation to achieve a uniform surface profile of 2.0 to 2.5 mils. Shop primed ferrous metal surfaces and fabricated assemblies shall be clean and dry prior to the application of field coats. Following assembly, the Contractor shall smooth welds and prominences using power tools prior to the application of the field applied coatings.


a. General: Prior to the application of field applied coatings, welds, back-to-back angles, sharp or rough edges and weld splatter shall be brushed with the specified prime coat and allowed to cure overnight.


7. Coatings:

a. Prime: One coat of the CSM’s recommended dry film thickness.

b. Finish: One or more coats of CSM’s recommended dry film thickness per coat to the specified system thickness.

K. Coating System Identification: S-1

1. Coating Material: Penetrating acrylic stain, color required.

2. Surface: Concrete

3. Service Condition: Non-immersed, exposure to moisture and sunlight.

4. Surface Preparation: Brush-off blast or industry standard acid etch or other preparation as approved by

the CSM.

5. Application:

a. General: Drying time between coats shall be as specified by the CSM for the site conditions.

b. Coatings: Minimum of two coats overall (coat as many times as required to achieve desired

color).

6. System Thickness: 200 square feet per gallon maximum or as recommended by the CSM.

7. Color Selection: As approved by the Construction Manager consistent with neighborhood selection.

The Contractor to price materials based on custom color.

L. Coating System Identification: S-2

1. Coating Material: Penetrating Water Repellent (Clear and Non-Film Building)

2. Surface: Concrete Floors

3. Service Condition: Exterior and Interior.

4. Surface Preparation: Clean surfaces of all traces of dirt, dust, efflorescence, mold, salt, grease, oil, asphalt, laitance, curing compounds, paint, coatings, and other foreign materials by brush-off blast, water blasting, and/or chemical cleaners or other preparation as approved by the CSM.

a. Concrete Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the CSM. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Loose concrete and laitance shall be removed from surfaces, and voids and cracks shall be repaired as specified in Section 03300.

5. Application:

a. General: Drying time before placing into service shall be as recommended by the CSM for site conditions.




09900 - 31


6. System Coverage: Follow CSM’s recommendations.

7. Color Selection: Clear.

M. Coating System Identification: S-3

1. Coating Material: Penetrating Water Repellent (Clear & Non-Film Building)

2. Surface: Concrete and Masonry Walls

3. Service Condition: Exterior and Interior – For Anti-Graffiti Applications

4. Surface Preparation: Clean surfaces of all traces of dirt, dust, efflorescence, mold, salt, grease, oil,

asphalt, laitance, curing compounds, paint, coatings, and other foreign materials

by brush-off blast, water blasting, and/or chemical cleaners or other preparation as

approved by the CSM.

a. Concrete Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to

the moisture content recommended by the CSM. Moisture content may be tested

by the Construction Manager with a Delmhorst Instrument Company moisture

detector, or equal. Loose concrete and laitance shall be removed from surfaces,

and voids and cracks shall be repaired as specified in Section 03300.

b. Masonry: Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint

defects shall be filled with mortar and repointed. Loose or splattered mortar shall

be removed by scraping and chipping. Masonry surfaces shall be cleaned with

clear water by washing and scrubbing to remove foreign and deleterious

substances. Muriatic acid shall not be used.

5. Application:

a. General: Drying time before placing into service shall be as recommended by the CSM for

site conditions.

6. System Coverage: Follow CSM’s recommendations.

7. Color Selection: Clear.




09900 - 32

3.06 COATING SYSTEMS SCHEDULE (FINISH SCHEDULE)

A. Specific coating systems, colors, and finishes for rooms, galleries, piping, equipment, and

other items that are coated or have other architectural finishes are specified in the

following coating system schedule. Unless otherwise specified in the coating system

schedule, the word "interior" shall mean the inside of a building or structure, and the

word "exterior" shall mean outside exposure to weather elements.

Coating Systems Schedule (Finish Schedule)

Location/Surface Coating System Identification Standard Color

A. General: All Surfaces not Specified by Area or Structure

1. Structural Steel, Metal Decking, and Galvanized Acoustical

Decking Uncoated or E-2

2. Equipment and Metal Appurtenances

a. Equipment, non immersed, unless otherwise specified

1) Indoors Factory Factory

2) Outdoors Factory Factory

b. Existing equipment

1) Not damaged nor modified by work in this contract Uncoated --

2) Damaged, exposed, or modified by work in this

contract

a) Indoors E-1 (see paragraph 3.02 ) Match existing

color

b) Outdoors EU-1 without primer (see

paragraph 3.02)

Match existing

color

c. Electrical switchgear panels, unit substations, motor

control centers, power transformers, distribution centers,

and relay panels; indoors and outdoors

See paragraph 3.03 Electrical

and Instrumentation Equipment

and Materials

ANSI 61 Grey

(outside)

FS 27880 White

(inside)

d. Instrumentation panels, graphic indicating panels,

indicating and transmitting field panels, unless

otherwise specified

1) Indoors See paragraph 3.03 Electrical


and Materials

FS 26306 Grey

(outside)

FS 27880 White

(inside)

2) Outdoors See paragraph 3.03 Electrical


and Materials

FS 27722 White

(outside)

FS 27880 White

(inside)

e. Existing electrical and instrumentation panels

1) Not damaged by work in this contract Uncoated --




09900 - 33



2) Damaged or exposed to outside surfaces by work in

this contract

a) Indoors E-1 (see

paragraph 3.02 Masonry

Surfaces)

FS 26306 Grey



Surfaces)

FS 26306 Grey

(Electrical)

FS 27722 White

(Instrumentation)

3. Conduit, Piping and Ductwork

a. Ferrous, non-ferrous and galvanized piping, and

appurtenant hangers and supports, non-immersed,

unless otherwise specified.

1) Indoors – noncorrosive E-1 FS 25051 Blue

2) Outdoors – noncorrosive EU-1 FS 20040 Brown

3) Indoors – in corrosive environment EA-1 To be determined

4) Buried piping M-1 or M-2 Not required

b. Ferrous piping, appurtenant and supports, immersed E-2 To be determined

c. Conduit, outlet and junction boxes, lighting transformers,

lighting, communication and small power panels, control

stations, piping, lagged ductwork, appurtenant hangers,

clamps, and supports on coated surfaces, unless

otherwise specified.

1) Indoors E-1 Match

background color

2) Outdoors EU-1 Match

background color

d. Conduit, outlets and junction boxes, lighting

transformers, lighting, communication and small power

panels, control stations, piping, lagged ductwork,

appurtenant hangers, clamps and supports on uncoated

surfaces, unless otherwise specified

1) Indoors E-1 FS 25051 Blue

2) Outdoors EU-1 FS 20040 Brown

e. Existing conduit, outlet and junction boxes, lighting

transformers, lighting communication and small power

panels, control stations, piping, lagged ductwork,

appurtenant hangers, clamps, and supports

1) Not damaged nor modified by work in this contract Uncoated --


contract

a) Indoors E-1 (see


Surfaces)

Match existing

color




09900 - 34





Surfaces)

Match existing

color

f. Racked conduits and cable trays Uncoated --

g. Insulated pipe jacketing Uncoated --

h. Plastic, fiberglass and flexible conduit and piping

1) Unless otherwise specified Uncoated --

2) PVC and CPVC Piping L-2 FS 25051 Blue

a) Exposed to direct sunlight L-2 FS 25051 Blue

4. Concrete, Grout, Masonry and Plaster

a. Immersed tank and channel walls and bottoms unless

otherwise specified Uncoated --

b. Outside concrete walls below grade common with dry

area or room In accordance with Section

07100

--

c. Walls and ceilings

1) Precast concrete or colored masonry Uncoated --

2) Outdoors, unless otherwise specified S-1 -To be

Determined

3) Indoors, unless otherwise specified E-4 FS 23617 Beige

d. Concrete equipment bases unless otherwise specified E-4 Match equipment

color

e. Floors unless otherwise specified S-2

f. Existing coated surfaces. L-1 Match existing

color

5. Handrails, Gratings, Floor Plates, Manhole Covers, and

Hatches

a. Unless otherwise specified Uncoated

b. Existing

1) Not damaged by work in this contract Uncoated --


contract

a) Indoors E-1 (see


Surfaces)

Match existing

color



Surfaces)

Match existing

color

6. Precast Concrete Metalwork

a. Fasteners, anchors, supports, etc. EU-1 Match wall

Notes:

1. Owner will select color from coating manufacturer’s list of EPA approved colors for potable water.




09900 - 35

3.07 INSPECTION AND TESTING BY OWNER

A. Inspection by the Owner or others does not limit the Contractor’s or CSA’s responsibilities

for quality workmanship or quality control as specified or as required by the CSM’s

instructions. Inspection by the Owner is in addition to any inspection required to be

performed by the Contractor.

B. The Owner may perform, or contract with an inspection agency to perform, quality control

inspection and testing of the coating work covered by this Section 09900. These

inspections may include the following:

1. Inspect materials upon receipt to ensure that are supplied by the CSM.

2. Inspect to verify that specified storage conditions for the coating system materials,

solvents and abrasives are provided.

3. Inspect and record findings for the degree of cleanliness of substrates.

4. Inspect and record the pH of concrete and metal substrates.

5. Inspect and record substrate profile (anchor pattern).

6. Measure and record ambient air and substrate temperature.

7. Measure and record relative humidity.

8. Check for the presence of substrate moisture in the concrete.

9. Inspect to verify that correct mixing of coating system materials is performed in

accordance with CSM’s instructions.

10. Inspect, confirm, and record that the "pot life" of coating system materials is not

exceeded during installation. Inspect to verify that recoat limitations for coating

materials are not exceeded.

11. Perform adhesion testing.

12. Measure and record the thickness of the coating system.

13. Inspect to verify proper curing of the coating system in accordance with the CSM's

instructions.

14. Perform holiday or continuity testing for coatings that will be immersed or coatings

that will be exposed to aggressively corrosive conditions.

3.08 FINAL INSPECTION

A. Contractor shall conduct a final inspection to determine whether coating system work

meets the requirements of the specifications.

B. The Construction Manager will subsequently conduct a final inspection with the

Contractor to determine the work is in conformance with requirements of the contract

documents.

C. Any rework required shall be marked. Such areas shall be recleaned and repaired as

specified at no additional cost to the Owner.




09900 - 36

09900-A Coating System Inspection Checklist

Project Name:

Owner Coating System Manufacturer(CSM)

General Contractor (GC) Coating System Applicator(CSA)

Area or Structure Location within Structure

Coating System (e.g. E-1) Coating Type (e.g. Epoxy, etc.)

Step Description Name Signature Date

1 Completion of cleaning and

substrate decontamination prior to

abrasive blast cleaning.

GC QC

CSM QC

CSA QC

2 Installation of protective enclosure

of structure or area and protection

of adjacent surfaces or structures

that are not to be coated.

GC QC

CSM QC

CSA QC

3 Completion of ambient condition

control in structure or building area

and acceptance of ventilation

methods in structure or Area.

GC QC

CSM QC

CSA QC

4 Completion of Surface Preparation

for Substrates to Be Coated.

GC QC

CSM QC

CSA QC

5 Completion of Primer Application. GC QC

CSM QC

CSA QC

6 Completion of Concrete Repairs If

Required and Related Surface

Preparation Rework Prior to Coating

System Application.

GC QC

CSM QC

CSA QC




09900 - 37

Step Description Name Signature Date

7 Completion of Concrete Filler/

Surface Application to Concrete.

GC QC

CSM QC

CSA QC

8 Completion of First Finish Coat

Application and of Detail Treatment

at Transitions or Terminations.

GC QC

CSM QC

CSA QC

9 Completion of Second Finish Coat

Application and of Detail Treatment

at Transitions and Terminations.

GC QC

CSM QC

CSA QC

10 Completion of Full and Proper Cure

of Coating System.

GC QC

CSM QC

CSA QC

11 Completion of Testing of Cured

Coating System including Adhesion,

Holiday (Continuity) Testing and Dry

Film Thickness.

GC QC

CSM QC

CSA QC

12 Completion of Localized Repairs to

Coating System Following Testing.

GC QC

CSM QC

CSA QC

13 Final Acceptance of Coating System

Installation Including Final Clean-Up

Complying with Specification

Requirements and the CSM's

Quality Requirements.

GC QC

CSM QC

CSA QC

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project General Requirements for Equipment



11000 - 1

SECTION 11000

GENERAL REQUIREMENTS FOR EQUIPMENT

GENERAL

1.01 DESCRIPTION

A. SCOPE:

1. This section specifies general requirements which are applicable to all mechanical

equipment. The Contractor is responsible for ensuring that all mechanical equipment

meets the requirements of this section in addition to the specific requirements of

each individual equipment specification section.

B. EQUIPMENT LISTS:

1. Equipment lists, presented in these specifications and as specified on the drawings,

are included for the convenience of the Construction Manager and Contractor and

are not complete listings of all equipment, devices and material required to be

provided under this contract. The Contractor shall prepare his own material and

equipment takeoff lists as necessary to meet the requirements of this project

manual.


A. ARRANGEMENT:

1. The arrangement of equipment shown on the drawings is based upon information

available to the Owner at the time of design and is not intended to show exact

dimensions conforming to a specific manufacturer. The drawings are, in part,

diagrammatic, and some features of the illustrated equipment installation may

require revision to meet actual submitted equipment installation requirements; these

may vary significantly from manufacturer to manufacturer. The contractor shall, in

determining the cost of installation, include these differences as part of his bid

proposal. Structural supports, foundations, connected piping, valves, and electrical

conduit specified may have to be altered to accommodate the equipment actually

provided. No additional payment shall be made for such revisions and alterations.

B. REFERENCES:

1. This section contains references to the documents listed below. They are a part of

this section as specified and modified. Where a referenced document cites other

standards, such standards are included as references under this section as if

referenced directly. In the event of conflict between the requirements of this section

and those of the listed documents, the requirements of this section shall prevail.












11000 - 2


later date, has been discontinued or has been replaced.

Reference Title

ABMA Std 9 Load Ratings and Fatigue Life for Ball Bearings

ABMA Std 11 Load Ratings and Fatigue Life for Roller Bearings

ANSI B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

ANSI B1.20.1 Pipe Threads, General Purpose (Inch)

ANSI B16.1 Gray Iron Pipe Flanges and Flanged Fittings, (Classes 25, 125, and 250)

ANSI B18.2.1 Square and Hex Bolts and Screws (Inch Series)

ANSI B18.2.2 Square and Hex Nuts (Inch Series)

ANSI S2.19 Mechanical Vibration – Balance Quality Requirements of Rigid Rotors,

Part 1: Determination of Permissible Unbalance, Including Marine

Applications

C. UNIT RESPONSIBILITY:

1. The Contractor shall cause equipment assemblies made up of two or more

components to be provided as a working unit by the unit responsibility manufacturer,

where specified. The unit responsibility manufacturer shall coordinate selection,

coordinate design, and shall provide all mechanical equipment assembly

components such that all equipment components furnished under the specification

for the equipment assembly, and all equipment components specified elsewhere but

referenced in the equipment assembly specification, is compatible and operates

reliably and properly to achieve the specified performance requirements. Unless

otherwise specified, the unit responsibility manufacturer shall be the manufacturer of

the driven component equipment in the equipment assembly. The unit responsibility

manufacturer is designated in the individual equipment specifications found

elsewhere in this project manual. Agents, representatives or other entities that are

not a direct division of the driven equipment manufacturing corporation shall not be

accepted as a substitute for the driven equipment manufacturer in meeting this

requirement. The requirement for unit responsibility shall in no way relieve the

Contractor of his responsibility to the Owner for performance of all systems as

provided in paragraph 00710-2.04.

2. The Contractor shall ensure that all equipment assemblies provided for the project

are products for which unit responsibility has been accepted by the unit responsibility

manufacturer(s), where specified. Unit responsibility for related components in a

mechanical equipment assembly does not require or obligate the unit responsibility

manufacturer to warranty the workmanship or quality of component products not

manufactured by them. Where an individual specification requires the Contractor to

furnish a certificate from a unit responsibility manufacturer, such certificate shall

conform to the content, form and style of Form 11000-C at the end of this Section,

shall be signed by an officer of the unit responsibility manufacturer's corporation and

shall be notarized. No other submittal material will be processed until a Certificate of

Unit Responsibility has been received and has been found to be satisfactory. Failure

to provide acceptable proof that the unit responsibility requirement has been

satisfied will result in withholding approval of progress payments for the subject

equipment even though the equipment may have been installed in the work.




11000 - 3

D. BALANCE:

1. Unless specified otherwise, for all machines 10 HP and greater, all rotating elements

in motors, pumps, blowers and centrifugal compressors shall be fully assembled,

including coupling hubs, before being statically and dynamically balanced. All

rotating elements shall be balanced to the following criteria:

N

GWU per

015.6=

a. Where:

Uper = permissible imbalance, ounce-inches, maximum

G = Balance quality grade, millimeters per second

W = Weight of the balanced assembly, pounds mass

N = Maximum operational speed, rpm

b. Where specified, balancing reports, demonstrating compliance with this

requirement, shall be submitted as product data. Equipment balance quality

grade shall be G 2.5 (G = 2.5 mm/sec) or better in accordance with ANSI S2.19.

PRODUCTS

2.01 FLANGES AND PIPE THREADS

A. Flanges on equipment and appurtenances provided under this section shall conform in

dimensions and drilling to ANSI B16.1, Class 125. Pipe threads shall conform in

dimension and limits of size to ANSI B1.1, coarse thread series, Class 2 fit.

B. Threaded flanges shall have a standard taper pipe thread conforming to ANSI B1.20.1.

Unless otherwise specified, flanges shall be flat faced.

C. Flange assembly bolts shall be heavy pattern, hexagonal head, carbon steel machine

bolts with heavy pattern, hot pressed, hexagonal nuts conforming to ANSI B18.2.1 and

B18.2.2. Threads shall be Unified Screw Threads, Standard Coarse Thread Series, Class

2A and 2B, ANSI B1.1.

2.02 BEARINGS

A. Unless otherwise specified, equipment bearings shall be oil or grease lubricated, ball or

roller type, designed to withstand the stresses of the service specified. Each bearing

shall be rated in accordance with the latest revisions of ABMA Methods of Evaluating

Load Ratings of Ball and Roller Bearings. Unless otherwise specified, equipment




11000 - 4

bearings shall have a minimum L-10 rating life of 50,000 hours. The rating life shall be

determined using the maximum equipment operating speed.

B. Grease lubricated bearings, except those specified to be factory sealed and lubricated,

shall be fitted with easily accessible grease supply, flush, drain and relief fittings.

Extension tubes shall be used when necessary. Grease supply fittings shall be standard

hydraulic alemite type.

C. Oil lubricated bearings shall be equipped with either a pressure lubricating system or a

separate oil reservoir type system. Each oil lubrication system shall be of sufficient size

to safely absorb the heat energy normally generated in the bearing under a maximum

ambient temperature of 60 degrees C and shall be equipped with a filler pipe and an

external level indicator gage.

D. All bearings accessible to touch, and located within 7 feet measured vertically from floor

or working level or within 15 inches measured horizontally from stairways, ramps, fixed

ladders or other access structures, shall either incorporate bearing housings with

sufficient cooling to maintain surface temperature at 65 degrees C or less for continuous

operation at bearing rated load and a 50 degrees C ambient temperature or shall be

provided with appropriate shielding shall be provided that will prevent inadvertent human

contact.

2.03 PUMP SHAFT SEALS

A. GENERAL:

1. Seals for wastewater pump shafts shall be mechanical seals. For industrial

wastewater service, or for fluids other than water or municipal wastewater, the

recommendations of the seal manufacturer shall be followed for selection of

appropriate seals. Unless specified otherwise, stuffing boxes and mechanical seals

shall conform to the requirements set forth in this paragraph.

B. MECHANICAL SEALS:

1. Unless otherwise specified in the detailed pump specifications, mechanical seals

shall be split mechanical seals requiring no field assembly, other than assembly

around the shaft and insertion into the pump. They shall be self-aligning, and self-

centering, single seals. They shall be of a nondestructive (nonfretting) type requiring

no wearing sleeve for the shaft. Shafts for pumps specified with mechanical seals

shall be furnished with no reduction in size through the seal area (no shaft sleeve).

Where the detailed specifications call for cartridge instead of split seals, all other

requirements of this paragraph apply.

2. Metal parts shall be Type 316 or 316L stainless steel. Springs shall be Hastelloy C,

Elgiloy, or other Duplex SS selected for resistance to chloride attack. Rotary faces

shall be silicon carbide or chrome oxide. Stationary faces shall be silicon carbide for

solids bearing fluid service and carbon for clean water service. Elastomers shall be

ethylene propylene or fluorocarbon. Mechanical seals shall be suitable for operation

between full vacuum (0 psia) up to 200 percent of the maximum specified operating

pressure, but in any event not less than 200 psig.

3. Seal chambers shall be provided with vented solids removal restriction bushings

except for enclosed line shaft pumps where the seal barrier fluid is used for line shaft

bearing lubrication. The bushing shall both control the amount of flushing water flow

and restrict solids and gas accumulation from the seal face area.




11000 - 5

a. Candidate seals include:

1) Chesterton 442 seals provided with Chesterton/SpiralTrac solids removal

restriction bushings Version N or D, as recommended by EnviroSeal

Engineering Products, Ltd, Nova Scotia, Canada.

2) AESSEAL RDS seals with Cyclops bushing.

3) John Crane 3710 seals with Type 24SL bushing.

4. Seals on pumps for contaminated water service (sludge, grit, wastewater, scum,

reclaimed water, etc.) shall be drilled and tapped for connection of a clean water

flushing supply.

2.04 COUPLINGS

A. Unless otherwise specified in the particular equipment sections, equipment with a driver

greater than 1/2 HP, and where the input shaft of a driven unit is directly connected to

the output shaft of the driver, shall have its two shafts connected by a flexible coupling

which can accommodate angular misalignment, parallel misalignment and end float, and

which cushions shock loads and dampens torsional vibrations. The flexible member

shall consist of a tire with synthetic tension members bonded together in rubber. The

flexible member shall be attached to flanges by means of clamping rings and cap screws,

and the flanges shall be attached to the stub shaft by means of taper lock bushings

which shall give the equivalent of a shrunk-on fit. There shall be no metal-to-metal

contact between the driver and the driven unit. Each coupling shall be sized and

provided as recommended by the coupling manufacturer for the specific application,

considering horsepower, speed of rotation, and type of service.

B. Where torque or horsepower capacities of couplings of the foregoing type is exceeded,

Thomas-Rex, Falk Steel Flex, or equal, couplings will be acceptable provided they are

sized in accordance with the equipment manufacturer's recommendations and sizing

data are submitted. They shall be installed in conformance to the coupling

manufacturer's instructions.

2.05 GUARDS

A. Exposed moving parts shall be provided with guards which meet all applicable OSHA

requirements. Guards shall be fabricated of 14-gage steel, 1/2-13-15 expanded metal

screen to provide visual inspection of moving parts without removal of the guard. Guards

shall be galvanized after fabrication and shall be designed to be readily removable to

facilitate maintenance of moving parts. Reinforced holes shall be provided. Lube fittings

shall be extended through guards.

2.06 CAUTION SIGNS

A. Equipment with guarded moving parts which operates automatically or by remote control

shall be identified by signs reading "CAUTION - AUTOMATIC EQUIPMENT MAY START AT

ANY TIME". Signs shall be constructed of fiberglass material, minimum 1/8 inch thick,

rigid, suitable for post mounting. Letters shall be white on a red background. The sign

size and pattern shall be as shown on the drawings. Signs shall be installed near

guarded moving parts.




11000 - 6

2.07 GAGE TAPS, TEST PLUGS AND GAGES

A. Gage taps shall be provided on the suction and discharge sides of pumps, blowers and

compressors. Pressure and vacuum gages shall be provided where specified. Gage

taps, test plugs, and gages shall be as specified in Divisions 15 and 17, respectively.

2.08 NAMEPLATES

A. Nameplates shall be provided on each item of equipment and shall contain the specified

equipment name or abbreviation and equipment number. Equipment nameplates shall

be engraved or stamped stainless steel and fastened to the equipment in an accessible

and visible location with stainless steel screws or drive pins.

2.09 LUBRICANTS

A. The Contractor shall provide for each item of mechanical equipment a supply of the

required lubricant adequate to last through the specified commissioning period.

Lubricants shall be of the type recommended by the equipment manufacturer and shall

be products of the Owner's current lubricant supplier. The Contractor shall limit the

various types of lubricants by consolidating them, with the equipment manufacturer's

approval, into the least number of different types. Not less than 90 days before the date

shown in his construction schedule for starting, testing and adjusting equipment (Section

01756), the Contractor shall provide the Owner with three copies of a list showing the

required lubricants, after consolidation, for each item of mechanical equipment. The list

shall show estimated quantity of lubricant needed for a full year's operation, assuming

the equipment will be operating continuously.

2.10 ANCHOR BOLTS

A. Anchor bolts shall be designed for lateral forces for both pullout and shear in accordance

with the provisions of Section 05502. Unless otherwise stated in the individual

equipment specifications, anchor bolt materials shall conform to the provisions of

Section 05502.

2.11 SPARE PARTS

A. Spare parts, wherever required by detailed specification sections, shall be stored in

accordance with the provisions of this paragraph. Spare parts shall be tagged by project

equipment number and identified by part number, equipment manufacturer, and

subassembly component (if appropriate). Spare parts subject to deterioration, such as

ferrous metal items and electrical components, shall be properly protected by lubricants

or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts

with individual weights less than 50 pounds and dimensions less than 2 feet wide, or 18

inches high, or 3 feet in length shall be stored in a wooden box with a hinged wooden

cover and locking hasp. Hinges shall be strap type. The box shall be painted and identi-

fied with stenciled lettering stating the name of the equipment, equipment numbers, and

the words "spare parts." A neatly typed inventory of spare parts shall be taped to the

underside of the cover.




11000 - 7

EXECUTION

3.01 INSTALLATION OF EQUIPMENT ACCESSORIES INCLUDED IN THIS SECTION SHALL BE AS

RECOMMENDED BY THE EQUIPMENT MANUFACTURER UNLESS OTHERWISE SPECIFIED IN

THE INDIVIDUAL EQUIPMENT SPECIFICATION SECTION.

END OF SECTION




11000 SUPPLEMENT 1 - 1

11000-C. UNIT RESPONSIBILITY CERTIFICATION FORM

[PROJECT TITLE]

CERTIFICATE OF UNIT RESPONSIBILITY

FOR SPECIFICATION SECTION _______________

__________________________________________________

[SECTION TITLE]

In accordance with Section 11000-1.02 Unit Responsibility of the contract documents, the undersigned manufacturer of driven

equipment (“manufacturer”) accepts unit responsibility for all components of equipment furnished to the Project under

specification Section______ , and for related equipment manufactured under sections___ ____, ______, and ______ .

We have reviewed the requirements for sections 11000 (where applicable) and all sections referencing this (these)

section(s), including but not limited to drivers, supports for driving and driven equipment and all other specified

appurtenances to be furnished to the Project by manufacturer. And, we have further reviewed, and modified as necessary,

the requirements for associated variable speed drives and motor control centers. We hereby certify that all specified

components are compatible and comprise a functional unit suitable for the specified performance and design

requirements whether or not the equipment was furnished by us. We will make no claim nor establish any condition that

problems in operation for the product provided under this specification Section ______ are due to incompatibility of any

components covered by this Certificate of Unit Responsibility. Nor will we condition or void any warranty for the

performance of the product of this specification Section ______ due to incompatibility of any components covered under

this Certificate of Unit Responsibility.

Our signature on this Certificate of Unit Responsibility does not obligate us to take responsibility for, nor to warrant the

workmanship, quality, or performance of related equipment provided by others under specification sections ______,

______, and ______. Our obligation to warranty all equipment provided by us shall remain unaffected.

Notary Public Name of Corporation

Commission expiration date Address

Seal: By:

Duly Authorized Official

Legal Title of Official

Date

Durham AWWTF – FOG Tank Retrofit Project Rigid Equipment Mounts



11002 - 1

SECTION 11002

RIGID EQUIPMENT MOUNTS

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies minimum requirements for rigid equipment mounts. Completed

equipment mounts shall consist of equipment pads, equipment anchors, and

mounting plates (baseplates, soleplates, or fabricated steel frames) set in grout.

2. Equipment mounts shall conform to the requirements specified in the Equipment

Mounting Schedule included in this specification. Where equipment mounting

requirements are not specifically identified in the Equipment Mounting Schedule, the

default mounting configuration for equipment shall consist of Pad Anchored

Equipment Pads per Detail C/S005, mounting plates leveled within 0.005 inch/foot,

anchored to the equipment pad with adhesive equipment anchors per Detail

C/S005, equipment anchor sleeve length is 10 times the bolt diameter, and the

mounting plate is grouted in position using non-shrink grout.

3. If a conflict exists between this section and requirements of individual equipment

manufacturers, the more restrictive requirements shall prevail.

4. Requirements for non-rigid equipment mounts (vibration isolation systems) are

specified in individual equipment specifications. Rigid equipment mounts conforming

to the requirements of this Section shall be furnished for the equipment pad and

other equipment mounting components supporting the vibration isolation system.

B. Definitions:

1. Specific equipment mounting terminology used in this section conforms to the

following definitions:

a. Baseplate: A mounting plate configured with a top plate and a perimeter edge of

the mounting plate that is below the top plate. Baseplates have a cavity between

the top plate and a horizontal plane at the bottom edge of the perimeter of the

mounting plate.

b. Soleplate: A machined or pre-formed mounting plate with a uniform horizontal

surface across the entire underside of the mounting plate, excepting shear

lugs/keys, grout pour holes, vent holes, and attachment hardware (nuts, bolts,

tapped holes, etc.). Soleplates have a top plate but lack the perimeter bottom

edge that extends below the underside of the top plate that is a defining feature

of baseplates.

c. Fabricated Steel Frame: An equipment mounting plate constructed of rolled steel

shapes and plates welded into a frame. Fabricated steel frames do not have top

plates.

d. Equipment Pad: Concrete foundation (block or slab) supporting and elevating

mounting plates above the supporting structural floor slab or local grade.

e. Mounting Pads: Milled/machined areas of baseplates, soleplates, and fabricated

steel frames where the feet or mounting surfaces of mounted equipment and

drivers are bolted to the baseplate, soleplate, or fabricated steel frame.




11002 - 2

f. Leveling Blocks: Steel blocks temporarily placed under baseplates, soleplates, or

fabricated steel frames at leveling positions (at equipment anchors) for the

purpose of leveling baseplates, soleplates, or fabricated steel frames prior to

grouting.

g. Shims: Thin stainless steel plates of uniform thickness used for fine adjustment

of level. Shims are used on top of leveling blocks for mounting plate leveling or

used between equipment drivers and baseplates, soleplates, or fabricated steel

frames for equipment alignment.

h. Wedges: Pairs of uniformly tapered metal blocks that are stacked with the

tapered surfaces reversed (relative to the other wedge) so that the top and

bottom surfaces of the wedges are parallel. Wedges are used between

equipment pads and baseplates, soleplates, or fabricated steel frames for the

purpose of leveling mounting plates.

i. Mounting Stud: Threaded rod or bolts anchored to baseplates, soleplates, or

fabricated steel frames for the purpose of mounting equipment or ancillary

devices onto baseplates, soleplates, or fabricated steel frames.

j. Reinforcement Dowels or Reinforcement Hooks: Steel reinforcement rods

embedded in concrete, across a cold joint, for the purpose of transferring loads

or force across the joint.

k. Leveling Position: A location on the top of a concrete equipment pad where

leveling tools and equipment will be temporarily installed or used for the purpose

of leveling baseplates, soleplates, and fabricated steel frames prior to grouting.

l. Grout Manufacturer: Refers to the manufacturer of the grout product used for

installation of rigid equipment mounts.

m. Grout Manufacturer’s Technical Representative(s): Refers to the technical

representative(s) of the Grout Manufacturer. The Grout Manufacturer’s Technical

Representative shall not be an employee of the Contractor.


A. References:

1. This section contains references to the following documents. Referenced documents

are a part of this section as specified and modified. In case of conflict between the



2. References to documents shall mean the documents in effect at the time of

Advertisement for Bids or Invitation to Bid. If referenced documents have been






date, whether or not the document has been superseded by a version with a later

date, discontinued or replaced.




11002 - 3

Reference Title

ACI 318, Appendix D Building Code and Commentary, Anchorage to Concrete

ANSI/HI 1.4 Centrifugal Pumps – Installation, Operation and Maintenance

ANSI/HI 2.4 Vertical Pumps – Installation, Operation and Maintenance

API RECOMMENDED

PRACTICE 686

Recommended Practices for Machinery Installation and Installation Design

ASTM E329 Inspection and Testing Agencies for Concrete, Steel, and Bituminous

Materials as Used in Construction

ASTM F593 Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F1554 Anchor Bolts, Steel, 36, 55 and 105 ksi Yield Strength

MIL-PRF-907E Anti-Seize Thread Compound, High Temperature

SSPC Society for Protective Coatings Specifications, Vol. 2

IBC International Building Code (including local amendments)

B. Quality Control By Contractor:

1. To demonstrate conformance with the specified requirements for rigid equipment

mounts, the Contractor shall provide the services of an independent testing

laboratory that complies with the requirements of ASTM E329. The testing laboratory

shall sample and test materials installed as part of rigid equipment mounts as

specified in this Section. Costs of testing laboratory services shall be borne by the

Contractor.

2. Where epoxy grout is specified in individual equipment specifications, the Contractor

shall furnish the services of a grout manufacturer’s technical representative who has

been factory trained by the grout manufacturer. The grout manufacturer’s technical

representative shall perform training and quality control of epoxy grout installation for

rigid equipment mounts as specified in this section.

C. Special Inspection for Equipment Anchors:

1. Equipment anchors shall comply with special inspection requirements specified in

Section 05502.

1.03 SUBMITTALS

A. The following information shall be provided in accordance with the submittal

requirements specified in Section 01330.

1. A copy of this specification section, including addendum updates, (referenced

sections need not be included for this Section) with each paragraph check-marked to

indicate specification compliance or marked to indicate requested deviations from

specification requirements. Check marks (✓) shall denote full compliance with a

paragraph as a whole. If deviations from the specifications are indicated, and

therefore requested by the Contractor, each deviation shall be underlined and

denoted by a number in the margin to the right of the identified paragraph,

referenced to a detailed written explanation of the reasons for requesting the

deviation. The Resident Project Representative shall be the final authority for

determining acceptability of requested deviations. The remaining portions of the

paragraph not underlined will signify compliance on the part of the Contractor with

the specifications. Failure to include a copy of the marked-up specification sections,

along with justification(s) for any requested deviations shall be sufficient cause for

rejection of the entire submittal with no further consideration. Copies of this




11002 - 4

specification section shall be numbered and marked (specification number and

equipment number) for inclusion (filing) with submittal materials furnished for

individual equipment specifications.

2. Name, employer, a copy of the employee’s Qualified Millwright card or other

equivalent certificate of journeyman qualifications for millwrights who will install rigid

equipment mounts, as specified in paragraph 3.03 Leveling.

3. Certificates or other documentation issued by the epoxy grout manufacturer that

demonstrates that the grout manufacturer’s technical representative has been

factory trained on installation of epoxy grout for equipment mounts, as specified in

paragraph 1.02 Quality Control by Contractor.

4. Shop drawings for equipment pads, equipment anchors, and baseplate, soleplate or

fabricated steel frame details. Shop drawings shall depict size and location of

equipment pads and reinforcement; equipment drains; equipment anchor, size,

location, and projection; expansion joint locations; elevation of top of grout and grout

thickness; elevation of top of baseplate, soleplate, or mounting block; size and

location of electrical conduits; and any other equipment mounting features

embedded in equipment pads. Shop drawings for equipment pads, equipment

anchors, and baseplate, soleplate, or fabricated steel frames shall be numbered and

marked (specification number and equipment number) for inclusion (filing) with the

associated equipment submittal requirements.

PART 2 PRODUCTS

2.01 GENERAL

A. Equipment mounts shall conform to the requirements specified in the Equipment

Mounting Schedule.

B. Equipment and drivers shall be rigidly mounted on a common mounting plate and

grouted into place on a concrete equipment pad unless alternate requirements are

specified in the Contract Drawings or the Equipment Mounting Schedule in this section.

Unless otherwise specified in the individual equipment specification, mounting plates

shall be anchored to equipment pads with a layer of grout between the equipment pad

and the mounting plate.

2.02 EQUIPMENT PADS

A. Materials:

1. Equipment pads shall be reinforced concrete as shown in Detail C/S005 in the

Drawings.

2. Minimum dimensions for equipment pads are shown on structural drawings where

the equipment pad is required to provide a minimum mass for vibration dampening.

B. Equipment Pad Drainage:

1. Equipment pads shall be furnished with 2-inch drains.

2. Locate equipment pad drains at drainage outlets from equipment or mounting plates

3. Route equipment drainage outlets or mounting plate drainage outlets to equipment

pad drains




11002 - 5

4. Route equipment pad drains to the floor drainage collection system.

5. Drainage piping for equipment pads shall be routed below the finished floor

elevation.

6. Exposed drain lines mounted on the floor are not acceptable.

Equipment Mounting Schedule

Equipment

Number

Specification Equipment

Grout

Type

Application

Notes Section Title Pad

Detail

Mounting

Plate

Leveling

Tolerance

(inch/foot)

Anchor Type

Anchor

Sleeve

Length

Default

Config.

Various Various Detail

C/S007

(foundation

anchored

equipment

pad)

0.005 Detail D/S007

(cast in place

anchors)

8D

Minimum

Non-

shrink

Default

equipment

mounting

configuration for

all equipment not

otherwise

specified in this

schedule

2.03 EQUIPMENT ANCHORS:

A. Equipment Anchor Materials:

1. Equipment anchors shall be all thread rod with heavy hex welded nuts, heavy hex

bolts, Post-installed anchors (wedge, sleeve, undercut, expansion, and adhesive

anchors), or adjustable canister anchors as specified in the Equipment Mounting

Schedule.

2. Post-installed anchors (wedge, sleeve, undercut, expansion, and adhesive anchors)

shall conform to the requirements of Section 05502.

3. Adjustable canister anchors shall be cast-in-place pre-manufactured adjustable

anchor inserts. Adjustable canister anchors shall provide a minimum of 6 inches of

vertical bolt height adjustment and lateral adjustment of the anchor bolt while

maintaining the anchor bolt in a true vertical orientation. Adjustable canister anchors

shall be Jakebolts as manufactured by Unisorb, Heavy Duty Adjustable Anchors as

manufactured by Deco, Rowan Adjustable Canister Anchor Bolt, or approved equal.

4. Equipment anchor materials shall conform to the following table for the area

exposure condition where the equipment is installed.

Area Exposure Equipment Anchor Materials

Indoor, Dry 304 Stainless, ASTM F593, Cond. CW

Indoor, Wet 304 Stainless, ASTM F593, Cond. CW

Outdoor 304 Stainless, ASTM F593, Cond. CW

Submerged, Immersed 316 Stainless, ASTM F593, Cond. CW

Process Corrosive 316 Stainless, ASTM F593, Cond. CW

Chemical Corrosive 316 Stainless, ASTM F593, Cond. CW




11002 - 6

B. Equipment Anchor Design:

1. The size (diameter) of anchors for clamping/fastening mounting plates to equipment

pads shall be as specified by the equipment manufacturer.

2. Equipment anchor size, embedment, and edge distance shall comply with the 2019

Oregon Structural Specialty Code and shall be sufficient to resist the maximum

lateral and vertical forces specified in Design Requirements for Nonstructural

Components and Nonbuilding Structures, Section 01612.

3. The Contractor shall furnish equipment anchor calculation submittals for FOG

Receiving Screen, FOG Tanks, Carbon Adsorbers, Pre-Engineered Metal Building, and

Rotary Lobe Pump. Equipment anchor calculations shall be furnished as product data

and submitted with equipment submittals. Equipment anchor calculations shall be

sealed by a registered structural or civil engineer licensed in the State of Oregon.

C. Equipment Anchor Tension:

1. Unless alternate bolt torque/tension requirements are specified by the equipment

manufacturer, equipment anchors shall be tightened to provide a final clamping

force that produces a tensile stress of 15,000 psi in each equipment anchor.

Adjustable canister anchors shall be tightened to the manufacturer’s maximum safe

working load. Equipment anchors consisting of Post-installed anchors shall be

tightened to manufacturer’s recommendations.

2. Bolt torque values required to produce the specified bolt tension based on well

lubricated plain finish national coarse thread bolts are presented in the following

table. Revise bolt torque values per equipment manufacturer’s recommendations for

alternate thread patterns, thread lubrication, bolt material, or bolt finish.

Bolt Diam. (in) 3/8 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2

Final bolt torque for 15,000 psi bolt stress (ft*lbs) 8 15 30 50 80 125 180 250 400

3. Prior to leveling and grouting mounting plates, grouted equipment anchors(Detail

A/M004) shall be pull tested to the values specified in the following table.

Anchor Diam. (in) 3/8 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2

Pull test load (kips) 2.1 3.8 6.1 9.1 13 17 22 28 43

D. Anchor Sleeves:

1. Equipment anchors shall be fitted with sleeves as specified in the Equipment

Mounting Schedule. Sleeve length for equipment anchors shall be 15 times the bolt

diameter unless otherwise specified in the Equipment Mounting Schedule. Sleeves

may be installed at the Contractor’s option if not specified in the Equipment

Mounting Schedule.

2. Adjust equipment anchor length/embedment depth shown in Detail D/S007 if

sleeves are not required.

3. Anchor sleeves shall be flexible polyurethane foam, steel cylinder/tubes, or ribbed

plastic sleeves.

4. Fill steel cylinders/tubes and ribbed plastic sleeves with a flexible room temperature

vulcanizing (RTV) sealant prior to embedment/installation.




11002 - 7

2.04 MOUNTING PLATES

A. General:

1. All baseplates, soleplates, and fabricated steel frames shall have edges of surfaces

bearing on grout rounded to a radius of not less than 0.25 inch.

2. Perimeter corners of baseplates, soleplates, or fabricated steel frames shall be

rounded to a radius of not less than 2.0 inches to avoid producing stress risers on

the grouted foundation.

3. Grout pouring holes (minimum 4 inches in diameter for epoxy grout, minimum 2.5

inches in diameter for cementitious non-shrink grout) shall be provided in all

baseplates and soleplates and all baseplates and soleplates shall have air release

holes.

4. Grout relief or vent holes (minimum 1 inch in diameter) shall be provided in all

baseplates and soleplates.

5. Mounting holes for equipment anchors shall be drilled through baseplates,

soleplates, and fabricated steel frames.

6. Mounting holes for equipment anchors shall be drilled. Mounting holes shall not be

burned out and they shall not be open slots.

7. Terminations requiring connections to baseplates and soleplates shall be acorn nuts

welded to the underside of the baseplate or soleplate or nuts welded to the

underside of the baseplate or soleplate and plugged with cork, plastic plugs or

grease.

8. Where fasteners terminate only into the baseplate, soleplate, or fabricated steel

frame, threaded lengths (tapped or embedded in mounting plates) shall be not less

than the bolt diameter.

9. Where baseplates, soleplates, or fabricated steel frames are leveled using

jackscrews, jackscrew threads shall be tapped in thickened pads or otherwise in

sufficient metal to provide ease in adjusting level.

10. Mounting pads and/or mounting surfaces for baseplates, soleplates, and fabricated

steel frames shall be milled flat after all welding and stress relieving and shall be

coplanar within 0.0005 inch per foot in all directions. Baseplates shall be pre-grouted

prior to milling.

11. Baseplates, soleplates, and fabricated steel frames shall provide common support

for the equipment and driver (and flywheel, if one is specified).

12. Baseplates, soleplates, and fabricated steel frames for equipment with drivers 20

horsepower and greater shall be furnished with transverse alignment (horizontal)

positioning jackscrews for alignment of equipment drivers on horizontal surfaces of

baseplates.

13. Alignment/positioning jackscrews shall be in perpendicular directions in a horizontal

plane at the mounting position for each corner or foot of the equipment driver.

(Additional jackscrews shall be provided for transverse alignment of the flywheel, if

flywheels are specified in the equipment specification.)




11002 - 8

14. Where specified in individual equipment specifications; baseplates, soleplates, and

fabricated steel frames shall be fitted with RK Fixators as manufactured by Unisorb,

or approved equal.

a. Fixators shall be installed at mounting surfaces for drivers.

b. Fixators shall be a three-piece wedge leveling adjustment device incorporating a

spherical washer assembly to provide true level height adjustment at each

mounting surface for the equipment driver.

B. Fabricated Steel Frames:

1. Fabricated steel frames shall be plate or fabricated structural steel mounting plates

with thickened steel mounting pads for bolting equipment to the mounting plate.

2. Fabricated steel frames shall be rectangular in shape, excepting fabricated steel

frames for centrifugal refrigeration machines and pumps which may be T- or L-

shaped fabricated steel frames to accommodate the equipment driver and

accessories.

3. Fabricated steel frames for split case pumps shall include supports for suction and

discharge elbows, if required by the specified configuration.

4. Perimeter members shall be I-beams or C-channel with a minimum depth equal to

1/10 of the longest dimension of the fabricated steel frame. Beam depth need not

exceed 14 inches provided that the deflection and misalignment is kept within

acceptable limits as determined by the manufacturer.

5. Fabricated steel frames shall be furnished with mounting pads welded to the

fabricated steel frame.

6. Surfaces of fabricated steel frames in contact with grout shall be sandblasted to

white metal per SSPC SP-5.

7. Apply a high-strength epoxy primer as specified in paragraph 2.06 within 8 hours of

sandblasting the fabricated steel frame.

C. Baseplates:

1. Baseplates shall be welded steel, cast steel, or cast iron with thickened mounting

pads for bolting equipment to the baseplate.

2. Internal stiffeners shall be provided on all cast and fabricated baseplates and shall

be designed to allow free flow of grout from one section of the baseplate to another.

3. The minimum acceptable opening in cross bracing and stiffeners shall be 2 inches

high by 6 inches wide.

4. All welds shall be continuous and free from skips, blowholes, laps and pockets.

5. Baseplates shall be pre-grouted at the factory after all welding has been completed

and prior to machining the mounting pads on the baseplate. Baseplates that have

not been pre-grouted at the factory shall be pre-grouted in the field by removing the

equipment from the baseplate, inverting the baseplate, and pre-grouting as specified

in this Section.

6. The underside of baseplates shall be sandblasted to white metal per SSPC SP-5 prior

to pre-grouting.

7. Pre-grouting shall be completed within 8 hours of sandblasting.




11002 - 9

8. Pre-grouting shall fill the underside of the baseplate to the bottom edges of the

baseplate.

9. Cast iron baseplates shall be sealed to prevent surface bleeding prior to shipment to

the project site.

D. Plate Steel Soleplates:

1. Plate steel soleplates shall be not less than 1.0 inch thick for equipment with drivers

greater than 30 horsepower.

2. Plate steel soleplates shall be furnished with grout keys/lugs or stiffeners on the

underside of the soleplate.

3. Excepting grout keys, grout pour holes, vent holes, and attachment hardware (nuts,

bolts, tapped holes, etc.) the underside of plate steel soleplates shall be a flat

uniform horizontal surface.

4. The underside of plate steel soleplates shall be scribed with the words “THIS SIDE

DOWN” using welding rod material prior to milling the mounting pads for equipment

or mounting surfaces.

5. Plate steel soleplates without grout pouring holes are acceptable provided that no

dimension of the soleplate (width or length) exceeds 18 inches.

6. Surfaces of plate steel soleplates in contact with grout shall be sandblasted to white

metal per SSPC-SP-5 prior to shipment to the project site.

7. Apply a high-strength epoxy primer as specified in paragraph 2.06 within 8 hours of

sandblasting the underside of plate steel soleplates.

8. Where equipment is fabricated or cast with feet or mounting surfaces that are not

fastened to a common baseplate or soleplate, as in dry-pit bottom-suction pumps,

the equipment may be supported on individual concrete piers or equipment pads in

lieu of mounting on a common equipment pad and soleplate. In such instances, the

equipment shall be supported at the feet or mounting surfaces on individual plate

steel soleplates, which shall be leveled and grouted into place on the individual piers

or equipment pads as specified in this section. Where multiple soleplates are

installed for an equipment installation, soleplates shall be installed coplanar within

0.002 inch/foot.

E. Polymer Concrete Soleplates:

1. Polymer Concrete Soleplates shall be pre-cast soleplates consisting of polymer

concrete with stainless steel inserts for equipment mounting.

2. Mounting surfaces on Polymer Concrete Soleplates shall be coplanar within 0.002

inch/foot. Polymer Concrete Soleplates shall be furnished with a uniform horizontal

surface over the entire underside of the mounting plate.

3. Excepting grout keys, grout pour holes and vent holes, the underside of soleplates

shall provide a flat uniform horizontal surface.

4. Polymer Concrete Soleplates shall be PoxyBase as manufactured by Basetek,

Chembase as manufactured by Goulds, or approved equal.

F. Corrosion Resistant FRP Baseplates:

1. Corrosion Resistant FRP Baseplates shall be pre-formed fiber reinforced plastic

fabrications.

2. Corrosion Resistant FRP Baseplates shall be products of the manufacturer of the

equipment that is mounted on the baseplate.




11002 - 10

2.05 GROUT FOR EQUIPMENT PADS

A. Epoxy Grout for Equipment Mounting:

1. Where epoxy grout is specified in the Equipment Mounting Schedule, grout for setting

bearing surfaces of baseplates, soleplates, and fabricated steel frames on

equipment pads shall be Epoxy Grout for Equipment Mounting as specified in Section

03600. Where the term epoxy grout is used in the context of details and

specifications for equipment mounting it shall mean Epoxy Grout for Equipment

Mounting as specified in Section 03600.

B. Cementitious Nonshrink Grout:

1. Where non-shrink grout is specified in the Equipment Mounting Schedule,

Cementitious Non-shrink Grout, specified in Section 03600, may be used for setting

bearing surfaces of baseplates, soleplates, or fabricated steel frames. Where the

term non-shrink grout or cementitious grout is used in the context of details and

specifications for equipment mounting it shall mean Cementitious Non-shrink Grout

as specified in Section 03600. Training and quality control by the grout

manufacturer’s technical representative is not required for rigid equipment mounts

installed with cementitious non-shrink grout.

2.06 EPOXY PRIMER

A. Epoxy primer shall be a high-strength, lead free, chrome free, and rust inhibiting two-

component epoxy primer specifically designed for use on metal substrates and in

conjunction with epoxy grout. The epoxy primer’s bond strength to sandblasted metal

shall not be less than 1500 psi. Epoxy primer shall be Phillybond Phillyclad 1000 Series,

or approved equal.

2.07 ANTI-SEIZE/ANTI-GALLING COMPOUND

A. Anti-seize or anti-galling compound shall be a molybdenum disulfide and graphite

combination in aluminum complex base grease conforming to MIL-PRF-907E. Acceptable

products include Jet Lube 550 by Jet Lube, Inc., E-Z Break by LA-CO, or approved equal.

2.08 PRODUCT DATA

A. The following information shall be provided in accordance with the product data

requirements specified in Section 01330:

1. Equipment anchor calculations demonstrating compliance with paragraph 2.03

Equipment Anchor Design.

2. Results of grout strength tests, as specified in paragraph 3.03 Grouting.

3. Completed Rigid Equipment Mount Installation Inspection Checklist Forms (Section

11002-SUPPLEMENT 1), as specified in paragraph 3.02 Epoxy Grout Quality Control.

4. List of Contractor’s equipment installation staff that has completed epoxy grout

manufacturer’s grout installation training specified in paragraph 3.02 Epoxy Grout

Training.




11002 - 11

PART 3 EXECUTION

3.01 GENERAL

A. General Requirements:

1. Roughen the underside of soleplates and fabricated steel frames and wipe with a

residue-free solvent as recommended by the epoxy primer manufacturer before

placement of the baseplate, soleplate, and fabricated steel frames on the equipment

pad for leveling. Roughen surfaces of mounting plates that will be in contact with

grout by power tool cleaning. Cleaning shall be performed by power wire brushing,

power sanding, power grinding, power tool chipping or power tool descaling. Cleaning

shall impart a minimum profile of 1.0 mil.

2. Prior to placement on the equipment pad for leveling, exposed grout surfaces of pre-

grouted baseplates shall be roughened and wiped with a residue-free solvent as

recommended by the manufacturer of the epoxy grout used for pre-grouting.

3. Prepare the underside of corrosion-resistant FRP baseplates and polymer concrete

baseplates per the baseplate manufacturer’s recommendations prior to placement of

the baseplate on the equipment pad for leveling.

4. Grout for equipment mounting shall be as specified in the Equipment Mounting

Schedule.

5. Grouting for installation of equipment on equipment pads shall take place prior to

connecting any field piping or electrical and instrumentation systems.

6. Unless the Resident Project Representative accepts an alternate installation

procedure in writing, baseplates, soleplates, and fabricated steel frames shall be

leveled and grouted with the equipment removed.

7. Pumps shall be installed in accordance with this section and ANSI/HI 1.4 or ANSI/HI

2.4, as appropriate for the type of pumping equipment installed.

8. Connecting piping with flexible connections and/or expansion joints shall be

anchored such that the intended function of these joints is maintained in the piping

system without imposing strain on the equipment connections.

B. Alternate Piping Connections:

1. Where an equipment manufacturer’s installation requirements include a rigid

connection between the machine and connecting piping systems, the Contractor

shall delete any flexible coupling (including equipment connection fittings) shown on

the drawings and install the equipment in the following manner, in lieu of installing

the flexible coupling:

a. The equipment pad shall be installed as shown on the detail specified in the

Equipment Mounting Schedule.

b. The baseplate, soleplate, or fabricated steel frames supporting the equipment

shall be installed, leveled, and grouted in place as specified in this section.

c. The piping shall be installed and aligned to the equipment connections and the

field piping connections without welding one of the joints for one section of pipe

between the equipment connection and the field piping and all valving. All

flanged joints shall be bolted up and pressure-tested.

d. All piping shall be fully supported by supports designed to accept their full weight

and thrust forces.




11002 - 12

e. The final sections of piping shall be aligned with the equipment and field

connections without the use of jacks, chain falls, or other devices to force it into

alignment.

f. The final piping joints shall be welded only after the previous steps have been

completed and accepted by the Resident Project Representative.

3.02 EPOXY GROUT TRAINING AND QUALITY CONTROL

A. Epoxy Grout Training:

1. Prior to commencing rigid equipment mount installation work on equipment pads,

the Contractor shall furnish the services of a grout manufacturer’s technical

representative to conduct a training school for the workers who will be using epoxy

grout for rigid equipment mount installations. The school shall be not less than

4 hours in length and shall cover all aspects of using the products, including form

construction for each equipment installation, surface preparation, mixing,

application, void prevention/elimination, and clean up. This requirement, however,

shall not be construed as relieving the Contractor of overall responsibility for this

portion of the work. The epoxy grout manufacturer shall furnish a list of school

attendees who have been satisfactorily trained to perform epoxy grout installation for

equipment mounting.

B. Epoxy Grout Quality Control:

1. For equipment mounted with epoxy grout, the epoxy grout manufacturer’s technical

representative shall provide quality control services for epoxy grout installation in

rigid equipment mounts. The epoxy grout manufacturer’s technical representative

shall be on site to inspect and verify that the installation personnel have successfully

performed surface preparation, epoxy grout application, and Quality Control

Inspection in accordance with these specifications for a representative portion of the

epoxy grout installation work.

2. Specifically, the epoxy grout manufacturer’s technical representative shall perform

the following services for at least one rigid equipment mount installation for each

equipment type and size installed with epoxy grout:

a. Inspect ambient conditions during various phases of epoxy grouting installation

for conformance with the epoxy grout manufacturer’s requirements.

b. Inspect the surface preparation of concrete substrates onto which epoxy grout

materials are to be applied, for conformance to the specified application criteria,

including but not limited to substrate profile, degree of cleanliness, and moisture.

c. Inspect the surface preparation of the metallic substrates onto which the epoxy

primer is to be applied.

d. Inspect the epoxy-primed metallic substrate for coverage and adhesion.

e. Inspect preparation and application of epoxy grout form work for conformance to

the specifications.

f. Inspect and record that the “pot life” of epoxy grout materials is not exceeded

during installation.

g. Inspect epoxy grout for cure.

h. Inspect and record that localized repairs made to grout voids conform to the

specification requirements.




11002 - 13

i. Conduct a final review of completed epoxy grout installation for conformance to

these specifications.

j. Attest to conformance of the Contractor’s work by signing appropriate entries in

the “Rigid Equipment Mount Inspection Checklist,” in Section 11002-

SUPPLEMENT 1.

3.03 INSTALLATION

A. Concrete Equipment Pad Preparation:

1. Roughen the top of the equipment pad after the concrete has reached its 28-day

compressive strength.

2. Remove all laitance and defective or weak concrete.

3. Roughened surface profile shall be 0.25 inch amplitude, minimum.

4. Expose broken aggregate without dislodging unbroken aggregate from the cement

matrix and without fracturing concrete and aggregate below the concrete surface.

5. Roughen using a light-duty (15 pounds or less), hand-held chipper with a chisel type

tool.

6. Abrasive blast, bush-hammer, jack hammers with sharp chisels, heavy chipping tools,

or needle gun preparation of concrete surfaces to be grouted are not acceptable.

7. Demonstrate removal of defective or weak concrete to the Resident Project

Representative prior to leveling.

8. The chipped surface of the concrete shall be such that the final elevation of the

equipment pad provides the grout manufacturer’s recommended thickness between

the surface of the equipment pad and the lower baseplate flange, underside of the

soleplate, or underside of the fabricated steel frame.

9. All dust, dirt, chips, oil, water, and any other contaminants shall be removed and the

surface protected with plastic sheeting until grout is installed.

10. Concrete equipment pad surfaces that have been finished smooth and level for use

as leveling positions shall be protected from damage during chipping activities.

Alternatively, leveling positions may be restored on chipped surfaces. Leveling

positions shall be restored by installing leveling blocks or leveling plates for

jackscrews on a high compressive strength epoxy putty (Philadelphia Resins,

Phillybond Blue 6A, or equal). Leveling blocks and leveling plates shall be installed

level on the epoxy putty.

B. Leveling:

1. Except where union rules require installation by another trade, all equipment and

machinery shall be mounted and leveled by a Qualified Millwright.

2. Use precision surveying equipment for leveling.

3. Machinists’ spirit levels will not be permitted for leveling purposes for any baseplate,

soleplate, or fabricated steel frame with a plan dimension greater than 4 feet.

4. Baseplates, soleplates, and fabricated steel frames shall be leveled to the tolerance

specified in the Equipment Mounting Schedule or as otherwise required by the

equipment manufacturer, if more stringent.

5. An anti-seize or anti-galling compound specified in paragraph 2.07 shall be applied to

all equipment anchor threads prior to beginning baseplate, soleplate, or fabricated

steel frame leveling.




11002 - 14

6. All baseplates, soleplates, and fabricated steel frames shall be leveled against steel

surfaces (jackscrew plates, leveling blocks, leveling nuts, support plates, or other

steel surfaces). Use of other materials for leveling purposes is strictly and specifically

prohibited.

7. Leveling equipment and tools shall be stainless steel leveling blocks and shims, steel

wedges, or jackscrews bearing on leveling plates.

8. Leveling nuts may be used for leveling baseplates, soleplates, and fabricated steel

frames weighing less than 200 pounds (including the weight of the equipment if

leveled with the equipment on the mounting plate).

9. Leveling blocks shall be stainless steel, 4 inches square and 1.5 inches thick with an

open-ended slot terminating in the center for the equipment anchor.

10. Leveling blocks shall be machined flat on all horizontal surfaces and placed under

the baseplate or soleplate at each equipment anchor.

11. Shims shall be pre-cut stainless steel, slotted for removal after grouting. Leveling

blocks and shims shall be coated with a light oil just prior to beginning the leveling

and grouting work. Shims shall be placed so the tabs on the shims are easily

accessible.

12. Clamp baseplates, soleplates, or fabricated steel frames in position (after leveling) by

installing the equipment anchor nuts and washers.

13. Bolt tension to fix the position of mounting plates during grouting shall be 30 to

60 percent of the final clamping force applied to clamp the mounting plate to the

equipment pad.

14. Prior to grouting, verify that the correct level and position of the baseplate, soleplate,

or fabricated steel frame has been maintained after clamping it to the equipment pad.

C. Grouting:

1. Design forms for a minimum of 6 inches hydrostatic head above the final elevation of

the grout.

2. Install grout expansion joints at 4 to 6 foot intervals, perpendicular to the centerline

of baseplates. Design expansion joints in accordance with the grout manufacturer’s

written instructions.

3. Coat forms with three coats of paste wax on all areas of the forms that will be in

contact with the grout.

4. Wax forms before assembly.

5. Prevent accidental application of wax to surfaces where the grout is to bond.

6. Remove any foreign material, such as oil, sand, water, wax, grease, etc., from

concrete surfaces that will contact grout before forms are installed.

7. Forms shall be liquid tight. Seal any open spaces or cracks in forms, or at the joint

between forms and the foundation using sealant, putty, or caulking compound.

8. Vertical and horizontal edges of the grout shall have 45-degree chamfers as specified

in equipment pad details. The 45-degree perimeter chamfer strip shall be located at

the final elevation of the grout.

9. Match chamfers in concrete portions of the equipment pad.

10. Install block outs at all leveling positions to allow removal of leveling equipment and

leveling nuts to be backed off after the grout has cured.

11. Coat jackscrews with a light oil or other acceptable bond-breaking compound prior to

grouting.




11002 - 15

12. Final elevation of grout on fabricated steel frames shall be at the top of the lower

flange of the perimeter I-beams or C-channel.

13. Top of grout elevation for baseplates and soleplates shall be at least 0.125 inch but

not more than 0.5 inch above the bottom or underside of the perimeter edge of the

baseplate or soleplate.

14. Seal equipment anchor sleeves to protect the sleeved length of the anchor from

contact with grout.

15. Wrap exposed portions of equipment anchors with duct tape to protect them from

grout splatter and to prevent bonding to grout.

16. Adjust ambient temperature to maintain mounting plate, foundation, and grout

temperatures to grout manufacturer’s recommended temperature.

17. Mix grout for equipment mounting in accordance with the grout manufacturer’s

written recommendations.

18. Epoxy grout shall be placed in a manner that avoids air entrapment, using a head box

to pour grout into the grout holes.

19. Place grout at one end of the baseplate or soleplate and work grout toward the

opposite end to force the air out from beneath the baseplate or soleplate.

20. Pour grout through a head box into grout pouring holes.

21. When the head box is moved to the next grout hole, a 6 inch standpipe shall be

placed over the grout hole and filled with grout.

22. Use of vibrating tools and/or jarring (rapping or tapping) forms to facilitate grout flow

is not permitted during placement of epoxy grout.

23. Never allow the grout in the head box to fall below the top of the baseplate or

soleplate once the grout has made contact with the baseplate or soleplate.

24. Grout placement shall be continuous until all portions of the space beneath the

baseplate, soleplate, or fabricated steel frame have been filled.

25. Prepare subsequent batches of grout prior to depleting the preceding batch.

26. Maintain grout height in standpipes after the space under the baseplate, soleplate,

or fabricated steel frame has been filled.

27. When the grout has started to take an initial set (typically this is determined by a

noticeable increase in temperature and no flow of grout at the vent holes) the

standpipes shall be removed and excess grout cleaned from all surfaces.

28. Check for leaks throughout grout pours. Leaks shall be repaired immediately to

prevent formation of voids.

29. Check baseplate, soleplate, or fabricated steel frame level and elevation before the

grout sets.

30. Cure grout in accordance with the grout manufacturer’s written instructions.

31. Where specified in the individual equipment specifications, a grout sample shall be

taken for each equipment pad.

a. Samples shall be placed in a cylinder of sufficient size to yield three 2-inch cubes

as test samples.

b. Samples shall be tagged with project name, date, time, the equipment number,

and ambient temperature at the time of placement.

c. Place samples next to the foundation of the equipment being grouted and cure

for 48 hours.




11002 - 16

d. Test grout samples in accordance with the grout manufacturer’s

recommendations.

e. Grout samples shall be tested by the independent testing laboratory specified in

paragraph 1.02 Quality Control by Contractor.

f. Test results shall be reported directly to the Resident Project Representative.

D. Completion:

1. Upon acceptance by the Resident Project Representative and the equipment

manufacturer’s representative and after the grout has reached sufficient strength,

grout forms and block outs at leveling positions shall be removed. Leveling blocks

and shims or wedges and support plates shall be removed, and leveling nuts and

jack screws shall be backed off to allow the grout to fully support the baseplate,

mounting block, or soleplate. Take care not to damage the grout during removal of

extended shimming material or leveling equipment and tools.

2. The equipment anchor nuts shall be tightened, using calibrated indicating torque

wrenches, to develop the full bolt tension specified in paragraph 2.03 Equipment

Anchor Tension.

3. Equipment anchor nuts shall be tightened in increments of not more than 25 percent

of the final torque value in an alternating pattern to avoid stress concentration on the

grout surface. After tightening equipment anchor nuts to final values, apply additional

wax, grease, or mastic to all exposed portions of the equipment anchor beneath the

baseplate, soleplate, or mounting block.

4. After applying additional wax or mastic to exposed portions of equipment anchors,

block outs (pockets) for access to leveling nuts, leveling blocks and shims, or wedges

shall be filled with the grout material installed under baseplates, soleplates, or

fabricated steel frames and pointed after the equipment anchor nuts have been

tightened to final values. Jackscrews shall be removed and holes in the baseplate,

soleplate, or fabricated steel frames filled with a flexible sealant (silicone rubber) or a

short cap screw.

5. Check for baseplate, soleplate, or fabricated steel frame movement (soft foot) by

individually loosening and re-tightening each equipment anchor. Vertical movement

at each equipment anchor shall be measured and recorded during loosening and

retightening and shall not exceed 20 micrometers (0.001 inch). Vertical movement

shall be measured using a magnetic-based dial indicator on the baseplate, soleplate,

or fabricated steel frame referenced to the epoxy grout surface of the equipment pad

or other approved method. Soft foot conditions shall be sufficient cause for removal

and reinstallation of grout and baseplates, soleplates, or fabricated steel frames.

6. Check for grout voids by tapping along the upper surfaces of the baseplate, soleplate,

or mounting block. Grout voids shall be sufficient cause for removal and

reinstallation of grout and baseplates, soleplates, or fabricated steel frames. Grout

voids shall be marked. At the discretion of the Resident Project Representative, grout

voids may be repaired as specified in Chapter 5, Section 3.16 of API RP 686.

3.04 FINAL INSPECTION

A. The Resident Project Representative will conduct a final inspection with the Contractor

for conformance to requirements of this section.

END OF SECTION





RIGID EQUIPMENT MOUNT INSTALLATION CHECKLIST

[CLIENT, PROJECT NAME]

Equipment Tag No.: Date:

Grout Product Name and Type:

Grouting System Manufacturer:

Grouting Application Contractor:

General Contractor:

Step 1: Verify Equipment Anchor Installation Conformance to Equipment Pad Details

Name: Contractor Rep. Date

Name: Construction Manager Date

Name: Millwright Date

Step 2: Completion of Cleaning and Concrete Substrate Preparation Prior to Grouting



Name: Grouting Contractor Rep. Date

Name: Grout Manufacturer’s Technical Rep. Date

Step 3: Equipment Leveling



Name: Millwright Date

Step 4: Installation of Protection of Adjacent Surfaces or Structures NOT TO BE GROUTED





Step 5: Preparation and Construction of Forms and Epoxy Grout Filling Standpipes





Step 6: Completion of Ambient Condition Control in Structure or Building Area and Acceptance of Ambient Conditions as They

Apply to Application and Curing Requirements for the Grouting System





Step 7: Epoxy Grout Installation





Step 8: Completion of Full and Proper Cure of Epoxy Grout









Step 9: Completion of Localized Repair of Grout Voids





Step 10: Final Acceptance of Grouting System Installation Including Final Clean-Up of the Work Site Complying with All

Specification Requirements and the GSM's Quality Requirements





Durham AWWTF – FOG Tank Retrofit Project FOG Screening Equipment



11131 - 1

SECTION 11131

FOG SCREENING EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes:

1. Self-contained fats, oils and grease (FOG) receiving screen.

2. Equipment control system and interface with Plant PLC and SCADA control systems.

B. Equipment List:

1. FOG Waste Screen.

2. FOG Inlet Control Valve.

3. FOG Waste Screen Control Panel.

4. FOG Waste Screen Pump Control Panel.

5. FOG Screen NPW/H Valve No. 1.



C. Related Sections include but are not necessarily limited to:

1. Division 01 - General Requirements.

2. Section 05502 – Anchors to Concrete and Masonry

3. Section 05505 - Miscellaneous Metalwork

4. Section 05520 - Metal Railings.

5. Section 11000 - General Requirements for Equipment

6. Section 11386 – Positive Displacement Rotary Lobe Pumps

7. Division 15 - Mechanical.

8. Division 16 - Electrical.

9. Division 17 - Control Systems.


A. Referenced Standards:

1. FOG receiving equipment and motor controllers shall, as applicable, meet the

requirements of the following industry standards:

a. AISI (American Iron and Steel Institute).

b. ABMA (American Bearing Manufacturers Association).

c. AGMA (American Gear Manufacturers Association).

d. NEMA (National Electrical Manufacturer’s Association).

e. NFPA (National Fire Protection Association).

f. ASTM (American Society for Testing and Materials).

g. AWS (American Welding Society Code).




11131 - 2

h. ASME (American Society of Mechanical Engineers).

i. NEC (National Electrical Code).

j. UL (Underwriters Laboratory Standards).

k. CSA Label Identification

1.03 SINGLE SOURCE RESPONSIBILITY:

A. Manufacturer’s Qualifications: Manufacturer shall have experience in manufacturing

equipment of similar size and configuration to the equipment specified herein. For a

manufacturer to be determined acceptable for providing the screening equipment on this

project, he must show evidence of a minimum of five installations and five years’

experience in the design and manufacturing of screening equipment of similar size and

type as specified herein.

B. All equipment described in this Specification shall be supplied by the screen

manufacturer. The manufacturer shall test-run the fully assembled machine in his factory

before shipment.

C. Screen manufacturer has unit responsibility for FOG Waste Screen Pump specified in

Section 11386. Refer to paragraph 11000-1.02D for Unit Responsibility requirements. A

certificate of unit responsibility shall be provided per Section 11000 Supplement 1.

D. The fog screen manufacturer shall be fully responsible for the design of the equipment

and integration of all system components to meet all design and performance

requirements specified herein.

E. Coordinate placement of manually operated equipment and appurtenances to locations

easily accessible to operator following installation of all systems and equipment included

in this Contract.

1.04 SUBMITTALS

A. Shop Drawings:

1. See Specification Section 01330 for requirements for the mechanics and

administration of the submittal process.

2. Requirements in Specification Section 11000.

3. A copy of this specification section, with addendum updates included, and all


paragraph check- marked to indicate specification compliance or marked to indicate

requested deviations from specification requirements.

4. A copy of the contract document control diagrams and process and instrumentation

diagrams relating to the submitted equipment, with addendum updates that apply to

the equipment in this section, marked to show specific changes necessary for the

equipment proposed in the submittal. If no changes are required, the drawing or

drawings shall be marked "no changes required". Failure to include copies of the

relevant drawings with the submittal shall be cause for rejection of the entire

submittal with no further review.

5. Source quality control test reports.




11131 - 3

6. Additional requirements:

a. List of components and catalog cuts fully describing all items.

b. Drawings for the control and starter panels to include enclosure front view and

interior layout of equipment.

c. Typical system description of operations. List component identification on

schematic diagrams. Identify all input/outputs to PLC.

d. Diagrams:

1) Network cable diagrams.

2) PLC wiring diagrams.

3) Panel ladder logic.

4) Interconnect drawings between plant PLC Control System and each control

panel.

5) Interconnect drawings between each control and starter panels and the

screen and auxiliary equipment.

e. List of recommended spare parts not supplied.

f. Copies of software for the PLC.

g. Operating description for control panels and PLC. Provide for back-up purposes a

copy of the software ladder logic covering all logic and sequences of operation.

Provide a soft copy of all documented PLC code on CD. Provide to Owner for

back-up purposes four software licenses of any PLC or Touchscreen OIT software

that is used. Provide a list of instrument settings.

7. Certifications:

a. Submit UL 508A label and compliance with required short circuit rating.

b. Supplier certification of proper installation and satisfactory performance.

B. Qualifications:

1. Provide control panels that are listed and labeled by UL, ETL, or other Nationally

Recognized Testing Laboratory (NRTL) as defined by OSHA regulations, or that have

been inspected and subsequent field-labeled by such NRTL.

2. Where listed components are installed in a common enclosure, the assembly shall be

listed and labeled per UL 508 and UL 508A or equivalent NRTL standard.

3. Each control panel shall be affixed with a UL 508A label "Listed Enclosed Industrial

Control Panel" or equivalent NRTL label prior to shipment to the jobsite

C. Software:

1. Provide two copies of unrestricted software for each equipment type:

a. PLCs.

b. VFDs.

c. Controllers.

d. Miscellaneous.

2. Provide software license for Owner’s usage as specified herein.

3. Provide two (2) cables of each type for connection from each equipment type to a

laptop computer.




11131 - 4

D. Programmed Settings:

1. For each PLC, etc. with programmable requirements, provide the final “as-built”

settings for all devices.

2. Submit on 8.5”x11” sheets in 3-ring binders.

3. Provide in accordance with the submittals section.

E. Operation and Maintenance Manuals:

1. See Specification Section 01782 for requirements for:

a. The mechanics and administration of the submittal process.

b. The content of Operation and Maintenance Manuals.

F. Anchor Bolts

1. Provide equipment anchorage calculations, cutsheets, and drawings in accordance

with Section 01612. Calculations shall be stamped by a licensed professional

engineer in the State of Oregon.

PART 2 PRODUCTS

2.01 ACCEPTABLE MANUFACTURERS

A. Candidate manufacturers and models are listed below. To conform to specified

requirements, the manufacturer’s standard product may require modification:

1. Fog Receiving Screen:

a. Flo-Septage Receiving Station DM: VFA-1200DM by Enviro-Care Co.

2.02 EQUIPMENT

A. Equipment Performance Requirements:

CONDITIONS UNIT

Number of Units 1

Influent Type Fats, oils and grease

Influent Average Solids Total Solids Concentration (mg/l) 35,000

Minimum flow performance required per screen (derating for sever FOG

characteristics) (gpm)

300

Maximum flow performance required per screen (gpm) 660

Perforation size (mm) 6

Screening/dewatering minimum Object Passing Capacity (inches) 3-1/8

B. Environmental Conditions:

1. The site of the work is at an elevation of approximately 150 feet above mean sea

level.




11131 - 5

C. Dimensional Requirements:

1. Layout configuration: As shown on Contract Drawings.

2.03 FEATURES

A. General:

1. Equipment provided shall be a fully automatic, self-cleaning, FOG receiving system

incorporating a perforated plate screen (rotating or stationary) and an integral screen

and screenings washing, screenings conveying and dewatering/compacting system

contained within a stainless steel tank.

2. Due to the abrasive nature of FOG containing grit and other abrasive materials, there

shall be no plastic-to-plastic or plastic to metal wearing surfaces in the unit.

3. Each unit shall be provided with a screen basket, exterior basket cleaning spray

bar(s), screening zone basket cleaning brushes, concentric transport screw with

integral screenings washing, dewatering and screenings compaction zone and “end-

less” bagger system to contain discharged screenings.

4. The system shall include basic start stop and status indicators at the hauler control

panel, along with all control logic required for the core operation and maintenance of

the system.

5. The system shall not include any software or programing associated with hauler

tracking, load tracking, keycard control, billing or other administrative functions.

6. Control and monitoring shall be fully compatible with the Plant PLC/SCADA system,

allowing for complete system monitoring from the plant PLC/SCADA system as well as

the vendor control panel.

B. Inlet Control Valve No. 1 and FOG Screen NPW/H Valve Nos. 1, 2, and 3.

1. Valves to the FOG screening system shall be provided.

2. The inlet valve shall be a non-lubricated eccentric plug valve conforming to the

requirements in Section 15110.

3. FOG Screen NPW and NPW/H Valves shall be solenoid valves or electrically actuated

ball valves conforming to the requirements in Sections 15050 and 15147.

4. Valve actuators shall conform to the requirements in Section 15185.

Conditions Unit

Maximum Available Spray Wash Water (gpm/psi) 50/60

Spray Wash Water Temperature (degree-F) 120-125

Power Supplies (V/P/Hz) 1) 480/3/60 2) 120/1/60

Screen Installation Location (indoor/outdoor) Outdoor-Covered

NFPA Classification Requirement Class 1 Division 1

Control Panel Locations (indoor/outdoor) Outdoor-Covered




11131 - 6

C. FOG Screen

1. Screening Basket:

a. The Drum Screen Basket shall be designed and built to withstand the maximum

possible static hydraulic forces exerted on the screen by the liquid flow.

Structural and functional parts shall be sized to prevent deflections or vibrations

that may impair the screening, conveying, washing and compacting operations.

b. The drum screen basket shall be of a cylindrical shape with perforations around

the entire basket.

c. The drum screen basket shall be only perforated plate with openings of 5 mm.

Bar screens, micro-bar screens, stepper screens, wire mesh or wedge wire shall

not be acceptable screen media.

d. The drum screen shall have no support arms on the influent side of the screen

basket to snag and accumulate long stringy solids. Screens with influent side

support arms will not be accepted.

e. Screening baskets part of a rotating drum system shall also provide the following:

1) The drum screen basket shall be mounted at the drive end using a large

diameter, single row, heavy duty industrial bearing assembly with integral ring

gear comprising part of the drive system. The bearing assembly shall have a

built in grease fitting.

2) The drum screen basket shall have angled lifting vanes to retain loose solids

during rotation and lift them up and into the screw auger trough. Helical

shaped vanes which can tumble screenings rather than lift screenings shall

not be accepted.

3) The screenings collection trough shall extend beyond the screen opening at

the influent end to maximize solids capture and reduce screenings recycle.

4) The drum screen basket shall be provided with a seal system incorporating

an HDPE seal. Any unit which does not incorporate this design shall not be

accepted.

f. The screen shall have a nominal 47 inch ID and be constructed of 3mm

(minimum) type 304L stainless steel plate.

2. Drum Screen Basket Cleaning Brush and Spray Bar(s):

a. The screening section of the FOG receiving system shall be positively cleaned

with a combination of mechanical brushes and high pressure spray water.

b. For rotating drum screening systems the screen shall be cleaned by a

combination of the following:

1) A high pressure stainless steel spray bar

2) An exterior stainless steel backed polypropylene brush cleaning brush in

constant contact with the screen basket, adjustable for brush wear

3) Rotating drum screen baskets shall continuously rotate in one direction

during the cleaning cycle and pass through the topmost portion where it is

cleaned by the spray bar and brush.




11131 - 7

3. Screenings Transport Screw and Dewatering Zone:

a. Screenings generated during the screening process, material larger than 5mm

diameter, shall be collected and transported out of the screening zone for

washing and dewatering prior to discharge into an owner provided dumpster.

b. For screening systems incorporating rotating drum screen in the screening

section the follow shall be required for screenings dewatering and conveyance:

1) The transport tube shall be provided with four (4) anti-rotation bars bolted

from the outside along the longitudinal axis. The screenings transport screw

shall not be dependent on the anti-rotation bars for support during normal

operation.

2) The screenings transport screw shall be constructed of type 304L stainless

steel.

3) The screenings collection trough shall be attached to the screenings

transport tube by a basket support flange. The screw drive assembly shall be

attached via a drive support flange welded to the upper end of the screenings

transport tube.

4) The concentric transport/dewatering screw shall be designed to transport

and dewater the screened material. The unit shall be provided with screw

flights of constant pitch approaching the compaction zone in order to prevent

clogging in the compaction zone. Designs incorporating a decreasing pitch

screw will not be accepted.

5) The screenings transport screw shall be supported by a sealed, self-

lubricating lower bronze bushing. The lower bushing shall be designed such

that it does not take any thrust load from the transport screw. Designs

requiring bearings of any type or externally lubricated bushing(s) or water

injection into the housing shall not be accepted.

6) The compaction zone shall be integral to the transport screw and compaction

tube. The compaction zone shall be designed to form a screenings plug and

return water released from the screened material back to the tank through

circular holes that are machined into the screenings compaction tube.

7) The compaction zone housing shall be fabricated entirely of stainless steel.

The lower body shall be a welded construction with a minimum of 10mm end

plates for maximum torsion resistance. The bottom of the compaction zone

shall be curved to promote maximum cleaning and minimum depositing of

materials. Units utilizing a fiberglass reinforced compaction zone housing will

not be accepted.

8) The compaction zone shall be furnished with a latched, hinged access cover

with a gasket. The access cover shall incorporate a safety interlock switch in

order to prevent operation of the unit with the access cover open. Units which

require the use of any tools to gain access to the compaction zone will not be

accepted.

4. Spray Wash Systems:

a. Each spray system shall be furnished with a slow closing, control solenoid valve,

stainless steel piping and fittings, flexible reinforced hoses and spray nozzles.

b. Automatic spray wash systems for the screen shall be constructed of stainless

steel piping and flexible reinforced hose. Spray wash system shall operate only

when the screen basket is rotating.




11131 - 8

c. Spray systems controls shall be such to allow for Hand, Off, Automatic, user

selectable operation.

d. For systems utilizing rotating drum screen in the screening zone the spray wash

system will consist of the following:

1) A lower wash system shall be located over the rotating basket, if present,

which utilizes a spray bar(s) with adequate spray nozzles to ensure a

consistent spray pattern over the entire length of the basket.

2) A screenings spray wash system shall be located in the lower section of the

transport tube to break up and return organic materials to the flow stream

and to ensure maximum screenings washing.

3) A compaction zone wash system shall be provided which periodically cleans

the compaction and dewatering zone via a stainless steel wash header

located in the uppermost end of the compaction/dewatering chamber. The

header shall be designed to completely wash the full surface of the transport

tube drainage area.

4) Total washwater consumption shall not exceed 48 gpm at 60 psi.

5. Tank:

a. The tank housing the screening systems shall be constructed from type 304L

stainless steel, incorporating covers, connections for odor control and spray wash

assemblies and associated mechanical screening equipment.

b. The vendor shall supply inlet and outlet flanges on the tank in locations such that

general operation and performance is not hindered and alignment is consistent

with the general arrangement outlined in the contract documents. .

c. For systems utilizing rotating drum screen in the screening zone the supplied

tank shall be as follows:

1) The FOG receiving unit shall be supplied with a two stage stainless steel tank.

The bottom of the influent section of the tank shall be sloped toward the

screen to eliminate sedimentation. The inlet section shall be sized to match

the inlet shape of the drum to prevent a wall for solids to dam and collect.

2) The second stage tank shall house the rotating drum screen unit.

3) The inlet stage of the tank shall be provided with a flush wash system.

4) The covers shall be hinged. Covers that are not bolted will have safety grating

or motor disconnects for safety. Tank and cover shall be spray water tight.

6. Equipment Drive Units:

a. For systems utilizing rotating drum screen in the screening zone the supplied

equipment drives shall be as follows:

1) The FOG receiving unit shall be a dual drive system which allows the drum

and screw to be driven independently to optimize solids removal.

2) Gear reducers shall be a helical gear type as manufactured by NORD or

approved equal. Provide a cast iron frame; design in accordance with AGMA

recommendations for Class I service.

3) Transport screw shall be directly driven by a flange mounted gear reducer.

4) The transport screw gear reducer shall be bolted to a machined flange

welded to the upper end of the transport tube.

5) The rotating screen drum basket shall be driven by a flange mounted gear

reducer using a spur gear and bull gear assembly.




11131 - 9

6) Gear reducers shall be driven by motors rated for a Class I, Div. 1, Group D

locations. Motor horsepower shall be determined by the screen’s basket

diameter.

7) Chain drives, belt drives, friction drives, or hydraulic drives will not be

accepted.

8) Designs incorporating a separate upper bearing for the transport screw will

not be accepted.

7. Electrical Controls and Devices:

a. FOG Waste Screen Control Panel:

1) The control panel shall include, but not be limited to, motor starters for drum

and auger, a PLC, panel-mounted touch screen (OIT), associated control and

pilot devices, and Corning DIN rail mounted fiber patch panel.

2) The system control panel shall be designed such that basic start stop control

and status indicators are available to all users. Operations set points and

controls shall be protected such that only authorized personnel shall have

access locally or through the plant PLC/SCADA system.

3) All components shall conform to electrical area classifications; non-

conforming components shall not be accepted.

4) The control panel shall provide control power to instrumentation associated

with this system.

5) Panel shall include the following components:

a) Enclosure, NEMA 4X.

b) UL508A label.

c) Short circuit rating for panel assembly: 35,000 amperes symmetrical at

480V.

d) Disconnect, with Door Interlocked Handle, lockable.

e) Constant speed starters, Rockwell, Eaton, Schneider or equal:

(1) Reduced-voltage solid-state (RVSS) soft starter with bypass for drum.

(a) Provide Allen-Bradley, Eaton or Square D products or equal.

(b) Starters shall be NEMA rated. IEC or NEMA/IEC rated devices not

permitted.

(c) Bypass contactor may be integral to the RVSS and is not required

to be NEMA rated.

(2) Full voltage starters permitted for auger motor.

f) Control Power Transformer, 480-120VAC w/branch circuit protection.

g) Pilot Lights.

(1) Control power on (white)

(2) Screen high level (amber)

(3) Drum running (red)

(4) Drum off (green)

(5) Drum fault (amber)

(6) Auger running (red)

(7) Auger off (green)

(8) Auger fault (amber)




11131 - 10

h) Push buttons (System Start, E-Stop, System Reset).

i) Selector Switches

(1) Drum Motor (HOA).

(2) Auger Motor (HOA).

(3) Wash Solenoids (HOA).

j) (1) Barrier relay (inspection door safety switch).

k) UPS is not required.

l) Programmable Logic Controller shall be Allen-Bradley MicroLogix series

1400 PLC, with Ethernet and Required I/O for communication and control

from the plant PLC/SCADA system.

m) Allen Bradley unmanaged Ethernet switch model number US05T.

n) Operator Interface Unit shall be Allen Bradley.

o) Panel Heater, with adjustable thermostat.

6) Data link to the plant PLC/SCADA system:

a) Provide a data link between the FOG Waste Screen Control Panel PLC and

the plant PLC/SCADA system consisting of Ethernet Communications

media and the Rockwell Ethernet/IP communications protocol. All

hardware, software and programming shall be furnished to implement

this data link along with supporting the Owner’s system integrator in the

integration of this data link into the plant PLC/SCADA system. The

Contractor shall assist the Owner’s system integrator in the integration of

the vendor PLC data base information into the plant PLC/SCADA system,

by supplying the Owner’s system integrator a Register Mapping Table of

all PLC holding register information. The intent of the data link is to allow

the plant PLC/SCADA system to monitor the parameters in the vendor

PLC. The parameters monitored by the plant PLC/SCADA system are the

same parameters used to display information on the local Operator

Interface Terminal. The control strategies also provide information on the

required signals to be provided to the plant PLC/SCADA system.

b) Provide both a PLC based run-time accumulator and a hardware run-time

meter. The PLC based run-time accumulator shall accumulate run hours

in tenths of hours and shall provide the totalized run hours on the OIT and

the plant SCADA. The reset for the vendor PLC based software shall by

restricted by security settings on the OIT.

D. Heat Tracing / Freeze Protection

1. The wash water lines shall be fitted with 120V, single phase, 60Hz flexible self-

regulating heat tracing wire and covered with a transport tube custom fitted

insulation blanket.

2. Compaction zone with heat pad and custom stainless steel cover.

3. Transition between influent tank and main tank shall be heated with two (2) heat

pads, insulation and protective 304 stainless steel covers.

4. Wiring from the wash water heat trace cables shall terminate in a factory mounted

junction box for field connection by Contractor.

5. The control panel shall include integrated heat trace circuits rated for the appropriate

wattage as determined by the manufacturer.




11131 - 11

6. GFCI circuit breaker added to control panel to power the heat tracing circuit.

7. One (1) ambient temperature thermostat shall be provided to control power to the

heat trace cable. The thermostat shall be 120 Volt, single phase, 60 Hz with a NEMA

4X housing. The temperature set point shall be selectable by and adjustable dial.

2.04 MAINTENANCE MATERIALS

A. Furnish Owner the following extra parts:

1. One (1) complete set of replacement brushes and necessary hardware.

2. One (1) solenoid valve build kit for each solenoid valve size.

3. Three (3) spare fuse sets of each size and type.

4. One (1) dozen replaceable bags.

PART 3 EXECUTION

3.01 INSTALLATION

A. See Section 11000.

3.02 INTERFACE WITH PLANT PLC/SCADA SYSTEM

A. The Contractor/Equipment Supplier shall assist the Owner’s system integrator in the

integration of the vendor PLC database information into the plant PLC/SCADA system by

supplying the Owner’s system integrator a Register Mapping Table of all holding register

information.

3.03 FIELD QUALITY CONTROL

A. The equipment shall be field tested in accordance with the requirements of Sections

01756 and 11000 to ensure compliance with specified requirements. The factory

service technician shall be present during the testing and shall make all necessary

adjustments and settings to the controls.

B. Following satisfactory completion of testing in accordance with the requirements of

Sections 01756 and 11000, the unit shall be tested for proper operation using a load of

FOG delivered by pumper truck, both gravity and pump discharged. The factory service

technician shall be present during this testing and shall make all necessary adjustments

and settings to the controls. The factory service technician shall demonstrate proper

operation of the entire unit.

C. Provide training of Owner’s personnel as specified in Section 01640.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Activated Carbon Adsorption Odor Control Equipment



11200 - 1

SECTION 11200

ACTIVATED CARBON ADSORPTION ODOR CONTROL EQUIPMENT

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies odor control packaged units with passive drum carbon

adsorbers with activated carbon and demister for odor reduction. The Engineer

assigns unit responsibility as specified in Section 11000-1.02 C to the activated

carbon Supplier for provision of new activated carbon as specified herein.

B. Type:

1. Passive drum carbon adsorber.

2. Virgin activated carbon shall be non-impregnated, high surface area, tightly packed

granular or pelletized type, specifically manufactured to absorb vapor phase organic

and malodorous compounds of the type typically generated from municipal

wastewater. Activated carbon shall be suitable for regeneration upon return to the

supplier. Supplier of activated carbon shall be experienced in the supply and

operation of activated carbon systems for vapor phase organic and hydrogen sulfide

removal at wastewater treatment facilities.

C. Equipment List:

Item Equipment number

FOG Tank 1 Passive Carbon Treatment 715OS4101

FOG Tank 2 Passive Carbon Treatment 715OS4102

D. Operating Conditions:

1. Activated carbon shall be specifically manufactured for continuous exposure to

moisture-laden foul air containing concentrations of hydrogen sulfide up to 10 parts

per million, as well as other malodorous compounds of landfill leachate origin such

as ammonia, organic sulfides, indols, skatols, aldehydes, and mercaptans. Foul air

will have temperatures ranging from 40 to 95 degrees F and relative humidity up to

100 percent. The odor control system shall meet the design requirements list in the

table below:

Design Air flow, cfm 40

Maximum temperature in vessel, degrees F 140

Maximum face velocity in bed, fpm 10

Minimum empty bed detention time, sec 3.6

Bed thickness, ft 3.0

Maximum H2S outlet at <1ppm inlet, ppm 0.05

Maximum H2S outlet at 1-10ppm inlet, ppm 0.1

Maximum H2S removal at >10ppm inlet, percent 99




11200 - 2


A. Unit Responsibility:

1. The Engineer assigns unit responsibility, as specified in Section 11000, to the

manufacturer of activated carbon provided under this section. This manufacturer is

the unit responsibility manufacturer and has unit responsibility, as specified in

Section 11000, for both the equipment assembly specified in this section and for all

other equipment assembly components specified elsewhere but referenced in this

section. A completed, signed Certificate of Unit Responsibility (Section 11000) shall

be provided.

B. Shipment, Protection and Storage:

1. The equipment shall be protected during shipment and storage as specified in

Section 01600.

1.03 SUBMITTALS

A. The following submittals shall be provided in accordance with Section 01330:



paragraph check-marked to indicate specification compliance or marked to indicate

requested deviations from specification requirements. A check mark ( ) shall

denote full compliance with a paragraph as a whole. If deviations from the

specifications are indicated, and therefore requested by the Supplier, each deviation

shall be underlined and denoted by a number in the margin to the right of the

identified paragraph, referenced to a detailed written explanation of the reasons for

requesting the deviation. The Engineer shall be the final authority for determining

acceptability of requested deviations. The remaining portions of the paragraph not

underlined will signify compliance on the part of the Supplier with the specifications.

Failure to include a copy of the marked-up specification sections, along with

justification(s) for any requested deviations to the specification requirements, with

the submittal shall be sufficient cause for rejection of the entire submittal with no

further consideration.

2. Completed Certificate of Unit Responsibility attesting that the Supplier accepts unit

responsibility in accordance with the requirements of this Section and Section

11000-1.02 Unit Responsibility. No other submittal material will be reviewed until

the certificate has been received and found to be in conformance with these

requirements.

3. Detailed product information for the activated carbon proposed for the job, including

verification of all properties specified in paragraph 2.02, as well as total weight per

bed.

4. Product information, including dimensional drawings, connection sizes, materials of

construction, and manufacturer’s catalog data.

5. Certified weights of the water-saturated carbon beds.

6. Performance curves developed for the specific application. Performance curves shall

show flow and expected pressure drop for the specified conditions.

7. Anchorage and seismic calculations per Section 01612 and Section 05502.

8. Operations and maintenance information per Section 01782.




11200 - 3

1.04 ENVIRONMENTAL CONDITIONS

A. The site of the work is at an elevation of approximately 150 feet above mean sea level.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. The Owner and Engineer believe the following candidate manufacturers are capable of

producing equipment and/or products that will satisfy the requirements of this Section.

This statement, however, shall not be construed as an endorsement of a particular

manufacturer’s products, nor shall it be construed that named manufacturers’ standard

equipment or products will comply with the requirements of this Section. Candidate drum

adsorber manufacturers include Evoqua, ECS Environmental Solutions, BIOREM, or

approved equal. Candidate carbon media manufacturers include Calgon Carbon

Corporation, Siemens/Weststates, Advanced Carbon Systems P-Series, or equal.

2.02 MATERIALS

A. Carbon

Virgin Activated Carbon

Substrate Bituminous coal or coconut shell

Particle size (U.S. Sieve) 4 mm pellet

CCl4 number percent by weight minimum (per ASTM D3467) 60

Hardness number minimum (per ASTM D3802) 95

Maximum moisture content percent by weight (per ASTM D2867) 2

Apparent density, gms/cc (per ASTM D2854) 0.46 - 0.60

Maximum head loss through bed at max flow rate, inches w.c./ft 1 4

H2S breakthrough capacity minimum, gms H2S removal/gm carbon 2 0.04

Notes:

1. Head loss shall be determined by passing dry air at 70 degrees F and 1 atm. pressure through a 2-inch

diameter by 12-inch deep bed of carbon placed in a dense packed arrangement per ASTM D2854.

2. The determination of H2S breakthrough capacity shall be made by passing a moist (70 percent RH) air

stream containing 1 percent H2S at 1,450 cubic centimeter per minute flow through a test bed of

uniformly packed activated carbon of the following dimensions: depth--9 inches, diameter--0.725 to

1.0 inch. The test shall be monitored to a 10 ppm breakthrough and the results expressed in gms H2S

removal/gm carbon which is calculated from the carbon sample weight uncorrected for moisture.

B. Canisters

1. The canisters shall be manufactured of 125 mil thick HMW-high density polyethylene

(PE), or equal. The canister shall have no moving parts. The canister shall support

the carbon bed on an inert plastic, air permeable structure. Canister design shall

utilize “Plug Flow” air distribution (Influent air shall enter below the carbon bed

support structure, this area shall pressurize equally, and the air pass through the

carbon bed uniformly, exiting through the outlet nozzle at the top of the vessel).




11200 - 4

2. The canister shall have the following features:

a. Carbon canister vessel of 304 stainless steel construction, including lockable

removable canister top

b. Initial load of activated carbon

c. 6” FNPT Air Inlet and Outlet Connections on canister

d. ¾” FNPT drain fitting with plug on canister

e. ¾” FNPT water regeneration overflow fitting with plug on canister

f. 4” PVC Butterfly valve on canister inlet

g. Rain cap with bird screen on air outlet

h. Skid mount for all above equipment

i. Grease filter/mist eliminator with 6” air inlet

j. Stainless steel ground rod assembly

3. The canister shall be capable of operating at an air flow rate of up to 200 CFM with a

maximum head loss of 4 inches W.C. The canister shall be rated at +3 psig.

C. Demister

1. A demister/ grease filter shall be installed upstream of the carbon

canisters. Demister housing shall be UV resistant black polypropylene. A ¾” NPT

half coupling with plug shall be included at the bottom of the housing for a

drain. Adequate clearance shall be provided under the unit for a drain elbow piping

and trap assembly. Nozzle end connections shall be 6” ANSI 150# FF flanges.

2. Packing material pad assembly shall consist of 2” thick 304 SS mesh pad, followed

by a 4” thick polypropylene mesh pad. A 1” thick 304 SS support frame shall be

included on each side of the polypropylene pad. Pad dimensions shall not exceed

24” wide x 24” high. Pad assembly shall be ACS Industries combination pad 8P/7CA

or equal. Differential pressure across the pacing assembly shall not exceed 1” WC at

a flow rate of 400 cfm. Packing shall be removable and replaceable.

3. A magnehelic differential pressure gauge shall be installed across the packing

assembly. Gage taps shall be ½” NPT half couplings. Differential pressure gauge

shall be Dwyer Model 2005 or equal. Tubing, fittings, mounting plate shall be field

assembled and installed by Contractor.

2.03 PRODUCT DATA

A. The following product data shall be provided in accordance with Section 01330:

1. A detailed description of the procedure for installation and commissioning of the

activated carbon.

2. Materials of construction for all components.




11200 - 5

PART 3 EXECUTION

3.01 INSTALLATION

A. The carbon shall be installed in strict accordance with manufacturer's recommendations.

Each bed shall be packed uniformly to the density specified with sample probes installed

in accordance with manufacturer's recommendations. The packed bed shall contain no

void pockets including bed areas around the sampling probes and near the vessel walls.

Each bed shall have a smooth surface with uniform bed depth throughout.

3.02 COMMISSIONING AND INSTALLATION

A. No on-site assistance shall be required. The modular adsorber unit shall come with

installation instructions which allow the operator to install the unit unassisted.

3.03 PERFORMANCE TEST

A. After completion of the commissioning period, each activated carbon bed shall be

subjected to a performance test. The performance test shall extend for one year. During

this year, the manufacturer shall supply a quarterly analysis of the activated carbon to be

reported as VOC capacity. The manufacturer shall furnish the sufficient number of

containers to accommodate three sampling levels in each compartment of each

activated carbon bed. The manufacturer shall also furnish instructions for sampling and

disposition.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Progressing Cavity Pumps



11315 - 1

SECTION 11315

PROGRESSING CAVITY PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. This Section Includes:

1. Positive displacement progressing cavity pump, complete with electric motor, and all

specified appurtenances, mounted on a common baseplate.

B. Equipment List:

Item Equipment no.

FOG Waste Feed Pump Shelf Spare

1.02 REFERENCES

A. This section contains references to the following documents. They are a part of this

section as specified and modified. Where a referenced document contains references to

other standards, those documents are included as references under this section as if

referenced directly. In the event of conflict between the requirements of this section and

those of the listed documents, the requirements of this section prevail.

B. Unless otherwise specified, references to documents mean the documents in effect at

the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the

Agreement if there were no Bids). If referenced documents have been discontinued by

the issuing organization, references to those documents mean the replacement

documents issued or otherwise identified by that organization or, if there are no

replacement documents, the last version of the document before it was discontinued.

Where document dates are given in the following listing, references to those documents

mean the specific document version associated with that date, regardless of whether the

document has been superseded by a version with a later date, discontinued, or replaced.

Reference Title

ABMA American Bearing Manufacturers’ Association

HIS Hydraulic Institute Standards

NEMA MG 1 National Electrical Manufacturer’s Association, Motors and Generators

1.03 DEFINITIONS

A. Terminology used in this section conforms to the ratings and nomenclature of the

Hydraulics Institute Standards.




11315 - 2

1.04 ADMINISTRATIVE REQUIREMENTS

A. Coordination:

1. See Section 01140 and 01324.

2. Coordinate pump and motor operational and starting characteristics with adjustable

frequency drive (AFD) settings used for control of this equipment. Incorporate the

following final AFD settings into the operation and maintenance submittal under

paragraph 1.06 Closeout Submittals:

a. Motor minimum operational speed

b. Motor maximum operational speed

c. Motor ramp up and ramp down speed, voltage, and hertz requirements

d. Other operating limits that are imposed by the driven equipment for operation

and warranty

B. Unit Responsibility:

1. The Contractor shall assign unit responsibility, as specified in Section 11000, to the

pump manufacturer for the equipment specified in this section. A certificate of unit

responsibility shall be provided.

1.05 SUBMITTALS

A. Action Submittals:

1. Procedures: Section 01330.

2. Sections to be marked-up and submitted include the following. Use check-marks ( )

to denote full compliance with a paragraph as a whole. Underline and denote

deviations with a number in the margin to the right of the identified paragraph.

Remaining portions of the paragraph not underlined signify the contractor’s

compliance with the specifications. Submit a detailed, written justification for each

requested deviation. Failure to submit a copy of the marked-up specification

sections, along with justification(s) for all requested deviations from the specification

requirements, with the submittal is sufficient cause for rejection of the entire

submittal with no further consideration:

a. This section

b. Section 11000: General Requirements for Equipment

c. Section 11002: Rigid Equipment Mounts

d. Section 16222: Low Voltage Motors up to 500 HP

e. Section 16262: Variable Frequency Drives 0.5-50 HP

3. Provide drawings showing general dimensions and confirming the size of pump,

motor, and specified appurtenances; piping connections; construction details of

equipment (including bearings); wiring diagrams; and weight of equipment.

4. Provide predicted performance curves developed for the specific application. Show

speed, capacity, head, horsepower, efficiency, and net positive suction head (NPSH)

required for the specified operating range.

5. Provide motor submittal information specified in Section 16222 and conform to the

requirements of this specification.

6. Submit detail drawings of the pump and driver unit foundation demonstrating

conformance to this section and Section 11002. Include drawings depicting type,




11315 - 3

size, number, projection, and arrangement of anchor bolts, and dimensional

drawings of the baseplates.

B. Informational Submittals:


2. Provide operating and maintenance information as specified in Section 01782,

including manufacturer’s warranties as specified.

3. Provide motor product data as specified in Section 16222.

4. Provide certification of satisfactory factory testing of each unit as specified in

paragraph 1.06 Quality Assurance. Include copies of test logs and resulting

performance curves.

C. Closeout Submittals:



A. Certifications:

1. Ensure that manufacturers proposing to furnish equipment specified under this

section hold current certification under ISO 9001-2001.

2. Application for certification under ISO 9001 is not an acceptable substitute for

current certification. Ensure that documentation attesting to current certification is

signed by an officer of the manufacturer’s corporation and notarized.

B. Performance Guarantee

1. Manufacturer must guarantee the pump performance specified in paragraph 2.03

Performance/Design Criteria. Ensure that the guarantee is in writing, signed by an

officer of the manufacturing corporation, and notarized. Under no circumstances can

deviations from the specified operating conditions result in overload of the driver

furnished with the equipment, nor can such deviations result in power requirements

greater than the driver’s nameplate (1.0 service factor) rating.

1.07 DELIVERY, STORAGE AND HANDLING

A. Procedures: Section 01600.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. The following candidate manufacturers are capable of producing equipment and/or

products that will satisfy the requirements of this section. The manufacturer’s standard

product may require modification provided the submittal equipment meets the specified

requirements and system operating conditions and conform to specified requirements:

1. Pumps:

a. Seepex

b. No Equal




11315 - 4

2.02 TYPE

A. Ensure that equipment furnished under this section is a positive displacement

progressing cavity pump.

2.03 SUPPLEMENT

A. Some specific requirements are attached to this Section as supplements.

2.04 PERFORMANCE/DESIGN CRITERIA

A. See specific requirements attached to this sectuion as supplements.

2.05 COMPONENTS

A. Stator:

1. The stator shall be molded in two halves and assembled with a segment retainer for

positioning of the stator halves, and adjusting segments to seal the stator halves and

adjust the stator clamp.

2. Flanged sealing sections shall be molded integral to the stator segments preventing

the metal stator tube from contacting the pumped liquid. Gaskets or "O" rings may

not be used to form this seal.

B. Accessories:

1. Stator Thermal Protection: provide for pump where indicated in the supplements and

as specified below:

a. Stator thermal protection (run dry protection) shall shut pump down before stator

damage occurs.

b. Provide thermowell drilled and tapped into stator and thermocouple for

measurement of temperature at pump stator to rotor interface.

c. Provide temperature controller in NEMA 4X enclosure, with dual display for stator

temperature and alarm set-point with adjustable hysteresis to prevent on/off

cycling of pump when coming off an alarm.

d. Provide thermocouple cable between thermocouple and temperature controller.

e. Temperature Controller Output: Dry contact SPDT rated for 5 amps at 120V ac.

Contact closes at high temperature to stop pump.

f. Temperature Controller Power Supply: 120V ac.

2. Equipment Identification Plates: Provide laminated phenolic plastic identification

plate securely mounted on each separate equipment component in a readily visible

location. Plate shall have white background and bear block type engraved black

enamel filled lettering.

a. Text (Indicated in this Section):

1) Descriptive Name: 1-inch high lettering.

2) Descriptive Tag: 1/2–inch high lettering.

b. Fastening: Secure with self tapping Type 316 stainless steel screws.

c. Size: 2-1/4-inch high plate.

3. Lifting Lugs: Equipment weighing over 100 pounds.




11315 - 5

2.06 FINISHES

A. Painting of equipment shall be in accordance with Section 09900.

B. All equipment and fabricated surfaces shall be shop primed and finish coated prior to

shipment from the factory.

2.07 SOURCE QUALITY CONTROL

A. Factory Tests and Adjustments: Test all equipment actually furnished.

B. Factory Test Report: Include test data sheets.

C. Functional Test: Perform manufacturer’s standard test on equipment.

D. Motor Test: See Section 16222, Low Voltage Motors up to 500 HP.

E. Performance Test:

1. Conduct in accordance with Hydraulics Institute Standards.

2. Perform under simulated operating conditions.

3. Test for a continuous 1-hour period without malfunction.

4. Test Log: Record the following:

a. Total head

b. Capacity

c. Horsepower requirements

d. Flow measured by factory instrumentation and storage volumes

e. Adjust, realign, or modify units and retest if necessary.

PART 3 EXECUTION

3.01 STORAGE

A. Pump specified in this Section shall be storage on project site. Coordinate with Owner for

delivery location.

3.02 SUPPLEMENT

A. The supplement listed below, following “END OF SECTION,” is a part of this Specification:

1. FOG Waste Feed Pump Shelf Spare Data Sheet.

END OF SECTION




11315 SUPPLEMENT - 1

FOG WASTE FEED PUMP SHELF SPARE DATA SHEET

Tag Numbers: Shelf Spare _

Pump Name: FOG Waste Feed Pump Shelf Spare _

Manufacturer and Model Number: (1) Seepex; BN 17-6LS _

SERVICE CONDITIONS

Liquid Pumped (Material and Percent): Fats, oils, and grease (FOG) _

Pumping Temperature (Fahrenheit): Normal: 80 _ Max: 100 _ Min: 50 _

Specific Gravity at 60 Degrees F: 1.0 _ Viscosity Range: _ 1 – 5 cP _

pH: 2 _

Abrasive (Y/N): Y _ Possible Scale Buildup (Y/N): N _

Inlet Pressure at Pump (psig): Minus 2 _

Min. Net Positive Inlet Pressure Available (feet): 27 _

PERFORMANCE REQUIREMENTS

Rated Capacity: 26 _ US gpm at _ 40 psi differential pressure.

Range (US gpm): 2-50 gpm _

Max/Min. Pump Speed (rpm): 250 / 16 _ Constant (Y/N): N _ Adjustable (Y/N): Y _

Speed Range: 7 % to 110 % of Rated Speed

Constant Torque (Y/N):

DESIGN AND MATERIALS

Pump Body Material: Gray cast iron _ Drive Housing Material: Gray cast iron _

Pump Stages: 1 _

Connections:

Suction: Flanged: X _ Flange Type: ANSI B16.5, 150# _ Size: 4-inch _

Screwed: ______

Discharge: Flanged: X _ Flange Type: ANSI B16.5, 150# _ Size: 3-inch _

Suction Port Orientation: See Drawings (side entry) _

Stator Material: Buna-N Stator Thermal Protection (Y/N): Y _

Rotor Material: Type 316 stainless steel _

Connecting Rod Material: 420 SST Drive Shaft Material: 420 SST _

Joints: Gear Type Universal (Y/N): Y Pin Type Universal (Y/N): N Other:_ _

Shaft Sleeve (Y/N): Material: _ _

Shaft Seal: Packing (Y/N): N Material: _ _

Lantern Ring (Y/N): Material: _ _

Mechanical Seal (Y/N): Y Type: Single Cartridge: SiC rotating / SiC stationary _

Mechanical Seal Manufacturer: John Crane _

Lubrication: _ _

ABMA B-10 Bearing Life (hrs): 50,000 Lubrication: Grease _




11315 SUPPLEMENT - 2

Coupling: Falk (Y/N): Fast (Y/N): _ _

Gear Type (Y/N): Manufacturer Standard (Y/N): Y _

Baseplate: Design: Fabricated Material: Carbon steel _

Drive Type: Direct-Coupled: X Belt: Hydrostatic Adjustable Speed: _

Close Coupled Gear Reducer: Other: Gear motor _

DRIVE MOTOR (SEE SECTION 16222, LOW-VOLTAGE MOTORS UP TO 500 HP)

Horsepower: 5 Voltage: 480 Phase: 3 Base Speed (rpm): 1800 _

Service Factor: 1.0 Inverter Duty (Y/N): Y _

Motor nameplate horsepower shall not be exceeded at any head-capacity point on pump curve.

Enclosure: DIP: EXP: ODP: TEFC: X CISD-TEFC: TENV: WPI: WPII: SUBM: _

Drive arrangement: In-Line: X Vertical “Z”: Piggy Back: _

Horizontal Offset: C-Face Mounted: _

REMARKS: _Mount pump and motor to common carbon steel baseplate. _

_ _

Durham AWWTF – FOG Tank Retrofit Project Positive Displacement Rotary Lobe Pumps



11385 - 1

SECTION 11386

POSITIVE DISPLACEMENT ROTARY LOBE PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. This Section Includes:

1. Positive displacement lobe pumps, convoluted rotor type. Ensure that equipment

furnished under this section is of a convoluted design to provide uniform pulse-free

flow, specifically designed for pumping Fats, Oils, and Grease (FOG).

2. Provide pumps that have not less than three rotor lobe tips to prolong the life of the

rotors.

3. Ensure that pumps are complete with electric motor and all specified appurtenances.

4. Pumping unit(s) consist of pump, shafting and couplings, electric motor, and all

specified appurtenances, mounted on a common baseplate, and associated

adjustable speed drives.

B. Equipment List:

Item Equipment no.

FOG Waste Screen Pump 715P6405

1.02 RELATED SECTIONS

A. This section contains specific references to the following related sections. Additional

related sections may apply that are not specifically listed below:

1. Section 03600: Grouting

2. Section 05502: Anchors to Concrete and Masonry

3. Section 09900: Painting and Coating

4. Section 11000: General Requirements for Equipment

5. Section 11002: Rigid Equipment Mounts

6. Section 11131: FOG Screening Equipment

7. Section 16222: Common Motor Requirements for Equipment

8. Division 16 – Electrical

9. Division 17 – Instrumentation

1.03 REFERENCES





those of the listed documents, the requirements of this section prevail.

B. Unless otherwise specified, references to documents mean the documents in effect at

the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the




11385 - 2


the issuing organization, references to those documents mean the replacement




mean the specific document version associated with that date, regardless of whether the

document has been superseded by a version with a later date, discontinued, or replaced.

Reference Title

AGMA 6010-E Spur, Helical, Herringbone, and Bevel Enclosed Drives

AGMA 6019-E Gear Motors Using Spur, Helical, Herringbone, Straight Bevel, or Spiral Bevel Gears

ASTM A470 Vacuum Treated Carbon and Alloy Steel Forgings for Turbine Rotors and Shafts

ASTM A536 Cast Iron Castings

1.04 DEFINITIONS

A. Terminology used in this section conforms to the following definitions:

1. Equipment pad: Concrete foundation (block or slab) supporting and elevating

equipment mounts above the supporting structural floor slab or local grade.

2. Mounting pads: Thickened or raised areas of baseplates and soleplates where the

feet or mounting surfaces of mounted equipment and drivers rest on the baseplate

or soleplate.

3. Baseplate: Fabricated (welded structural steel elements), cast, or plate steel base,

with or without grout fill, as specified, providing a common mounting element on

which the legs, feet, or mounting surfaces of equipment (pump, gearbox, and motor)

are mounted by bolted connections.

4. Pump drive configuration types:

a. “B” or close-coupled “block”: Close-coupled pump configuration employing a

direct coupled motor and gear reducer or gear motor such that the

motor/reducer combination provides the pump’s shaft bearing support.

b. “BA-D” or “bearing assembly-direct”: Separate bearing frame assembly between

the gear reducer and pump providing the pump’s shaft-bearing support, with the

gear reducer directly connected to the motor.

c. “BA-V” or “bearing assembly-V belt”: Separate bearing frame assembly between

the gear reducer and pump providing the pump’s shaft-bearing support, with the

gear reducer connected to the motor by V-belt.

5. “Universal joint”: Rigid connecting rod with lubricated joints at each end connecting

the pump drive shaft to the rotor (excludes flexible connecting shaft drives).

6. “Flexible shaft”: Flexible shaft with rigid joints at each end connecting the pump drive

shaft to the rotor (excludes universal joint drives).


A. Coordination:

1. See Section 01140 and 01324.

2. Coordinate pump and motor operational and starting characteristics with adjustable

frequency drive (AFD) settings used for control of this equipment. Incorporate the




11385 - 3

following final AFD settings into the operation and maintenance submittal under

paragraph 1.06 Closeout Submittals:

a. Motor minimum operational speed

b. Motor maximum operational speed

c. Motor ramp up and ramp down speed, voltage, and hertz requirements

d. Other operating limits that are imposed by the driven equipment for operation

and warranty

B. Unit Responsibility:

1. The Contractor shall assign unit responsibility, as specified in Section 11000, to the

FOG screening equipment manufacturer specified in Section 11131.

1.06 SUBMITTALS



2. Sections to be marked-up and submitted include the following. Use check-marks ( )

to denote full compliance with a paragraph as a whole. Underline and denote







submittal with no further consideration:

a. This section

b. Section 05502: Anchors to Concrete and Masonry

c. Section 11000: General Requirements for Equipment

d. Section 11002: Rigid Equipment Mounts

e. Section 16222: Common Motor Requirements for Equipment

f. Section 16262: Variable Frequency Motor Controllers

3. Provide drawings showing general dimensions and confirming the size of pumps,

motors, drives, and specified appurtenances; piping connections; construction details

of equipment (including bearings); wiring diagrams; and weight of equipment.

4. Provide predicted performance curves developed for the specific application. Show

speed, capacity, head, horsepower, efficiency, and net positive suction head (NPSH)

required for the specified operating range.

5. Provide motor submittal information specified in Section 16222 and conform to the

requirements of this specification.

6. Submit detail drawings of the pump and driver unit foundation demonstrating

conformance to this section and Section 11002. Include drawings depicting type,

size, number, projection, and arrangement of anchor bolts, dimensional drawings of

the baseplates, and dimensional drawings for the concrete support pad for the

equipment. Have the drawings depict all other pertinent information, including:

location of equipment pads and reinforcement, equipment drains, elevation of top of

grout and grout thickness, elevation of top of baseplate or mounting block, size and




11385 - 4

location of electrical conduits, and any other equipment mounting features

embedded in equipment pad.

7. Provide equipment anchorage calculations, cutsheets, and drawings in accordance

with Section 01612. Calculations shall be stamped by a licensed professional

engineer in the State of Oregon.



2. Provide a letter of confirmation of suitability of variable frequency drives being

provided by the FOG screening equipment manufacturer for this equipment in

accordance with Section 16262.

3. Identify coordination items required for proper setup of the AFD as specified in

paragraph 1.05 Coordination.

4. Provide operating and maintenance information as specified in Section 01782,

including manufacturer’s warranties as specified and record of final AFD

configuration settings.

5. Provide motor product data as specified in Section 16222.

6. Provide certification of satisfactory factory testing of each unit as specified in

paragraph 1.07 Quality Assurance. Include copies of test logs and resulting

performance curves.

C. Closeout Submittals:


2. Submit Installation Certification Form from Section 01756

3. Submit training documents per Section 01640.


A. Certifications:

1. Ensure that manufacturers proposing to furnish equipment specified under this

section hold current certification under ISO 9001-2001.

2. Application for certification under ISO 9001 is not an acceptable substitute for

current certification. Ensure that documentation attesting to current certification is

signed by an officer of the manufacturer’s corporation and notarized.

B. Performance Guarantee

1. Manufacturer must guarantee the pump performance specified in paragraph 2.03

Performance/Design Criteria. Ensure that the guarantee is in writing, signed by an

officer of the manufacturing corporation, and notarized. Under no circumstances can

deviations from the specified operating conditions result in overload of the driver

furnished with the equipment, nor can such deviations result in power requirements

greater than the driver’s nameplate (1.0 service factor) rating.






11385 - 5

1.09 SPECIAL WARRANTY

A. Special Warranty: Have the manufacturer warrant Positive Displacement Rotary Lobe

Pump against defects in materials and workmanship for 2 years.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. The following candidate manufacturers are capable of producing equipment and/or

products that will satisfy the requirements of this section. The manufacturer’s standard

product may require modification provided the submittal equipment meets the specified

requirements and system operating conditions and conform to specified requirements:

1. Pumps:

a. Swaby LOBELINE

b. No Equal

2.02 TYPE

A. Ensure that equipment furnished under this section is a positive displacement lobe

pump.

2.03 PERFORMANCE/DESIGN CRITERIA

A. Service Conditions:

Description Value

Equipment number 715P6405

Area exposure Covered, outdoors

Fluid type The fluid to be pumped is water; fats, oil and grease

(FOG) and the percent solids may vary up to 7%

solids.

Fluid temperature 40 – 100 degrees (°)F

Fluid pH 6 to 8

Percent Solids 4-7%

Control Variable speed based on flow setpoint

B. Operating Conditions:

1. Design and select equipment for continuous duty pumping of concentrated solids

derived from the treatment of wastewater.

2. Ensure that pumps are suitable for exposure to fats, oil and grease (FOG) containing

grit, small particles of wood, metal, industrial solvents, greases, detergents,

petroleum products, and organic particles.




11385 - 6

C. Performance Requirements:

Operating Condition Value

Equipment 715P6405

Rated Capacity, gpm 300

Rated Head, psi 19.6

Maximum pump speed at rated capacity and

head, rpm

239

Motor HP 15

Variable speed drive Adjustable frequency

VFD speed at rated pump capacity, percent 100

D. Design Requirements:

Item Value

Equipment number 715P6405

Pump

Drive type Bearing assembly-direct (Type BA-D)

Piping connection size, inches

Pump suction 6

Pump discharge 6

Operating speed at rated capacity, rpm, maximum 250

Operating speed, rpm, maximum 250 or manufacturer’s recommended speed,

whichever is lower

Variable frequency drive (VFD) Yes

Motor (See Section 16222)

Horsepower, maximuma 15

Type (See Section 16222) Project defined TEFC: (Corrosion) Severe Duty,

Enclosed

Inverter duty Yes

Space heater Yes

Thermal protection Yes

Ambient duty rating +40

Operating speed, rpm, maximum 1,800

Voltage rating 460-volt, 3 Phase

Hazardous rating None

Reversing motor No

Multispeed motor No

Motor starting type VFD, coordinate for proper starting of driven

equipment.

Voltage rating 460-volt, 3 Phase

Notes:

a The motor size must be based on non-overloading of the motor at maximum pump speed against a

discharge head of 50 psi.




11385 - 7

2.04 SYSTEM OPERATION:

A. The pump will be installed outdoors at an elevation of 160 to 165 feet above sea level.

The pump will be controlled by the FOG Screening Equipment control system (see Section

11131). Pumps will be started and stopped and pump speed will be adjusted in

response to changing FOG flow.

2.05 MATERIALS

A. Materials specified are considered the minimum acceptable for the purposes of

durability, strength, and resistance to erosion and corrosion. The contractor may propose

alternative materials for the purpose of providing greater strength or to meet required

stress limitations. However, alternative materials must provide at least the same

qualities as those specified for the purpose.

B. Ensure that materials conform to the requirements of API 610, Materials Class I-2 with

the following conditions:

Component Material

Pump Gearcase ASTM A48-76 Grade 30

Pump Rotorcase Stainless Steel AISI 316

Radial Wear Plates Stainless Steel ASTM A743 (CD4-MCU)

Rear Wear Plates Stainless Steel ASTM A240 (Duplex 2205)

Rotors Stainless Steel ASTM A743 (CD4-MCU)

Shafts AISI 4340 HT, carbon steel

Shaft Sleeves Included with Mechanical Seals

2.06 MINIMUM REQUIRED FEATURES

A. Pumps shall be heavy-duty lobe pumps industrial type. Each pump shall be capable of bi-

directional rotation and shall be able to run dry for an infinite period of time.

B. Pumps shall be designed with an open air space (minimum 5.5”) between the pumping

head containing the sludge and the timing gear box such that a leak in the shaft seal will

allow sludge to run onto the floor and not into the timing gear box. An oil-filled seal

chamber is not acceptable.

C. Pumps shall be designed with replaceable rear and radial wear plates with attachments

from the external area of the pump.

D. Pumps shall be designed with rotors and gears that connect shafts with a splined and

taper-lock arrangement for the gears. Keyways are not acceptable.

E. Pumps shall be designed with a ductile-iron rotor case with integral flanges. Multiple

piece rotorcase which includes fabricated flange connections are not acceptable.

Rotorcase shall be one piece casting including flanges.

F. Pumps shall be designed without end bearings. End bearings will not be acceptable.

G. Only one (1) upper rotor and one (1) lower rotor shall be provided on the pump. The use

of multiple, stacked rotors shall not be allowed.




11385 - 8

H. The rotors shall be of tri-lobe design. In addition the tips shall be parallel to the axis of

rotation of the rotor. Helical, convoluted or twisted rotors shall not be allowed.

I. The rotors must be capable of being removed individually. Pumps which require the

simultaneous removal of both rotors shall not be accepted.

J. In order to maintain continuous availability and immediate supply of pump and

replacement parts, pump and pump components, such as but not limited to: castings,

shafts, mechanical seals, timing gears, wear plates, rotors, shall be manufactured,

machined and assembled in the USA. Certification of US manufacturer including foundry

certification will be supplied at the engineer’s request.

2.07 COMPONENTS

A. Rotorcases:

1. The rotor case shall be constructed of AISI 316 Stainless Steel incorporating 150 lb.

ANSI B16.1 flat faced drilled flanged connections. The pump flanges shall be

integrally cast with the rotor case. Multiple Piece Design Pump Casings, which

includes separate flanges, held together by screw connections are not acceptable.

Fabricated ports/flange connections are not acceptable.

2. The internal rotor case surface shall provide a smooth transition from circular ports

connections at the flanges, to a full width rectangular port at rotor chamber, with a

greater cross sectional than at the flanged port connection, to allow for unimpeded

passage of solids.

3. The front of the rotor case shall incorporate an O-ring to form a reusable seal for the

front cover. All fasteners shall be stainless steel.

4. The rotor case bore shall be fitted with removable restriction bushings enabling the

removal of the shaft sleeve or mechanical seals and O-rings through the rotor case

without requiring its removal.

5. An open area (air gap) shall be provided between the rotor case and the gear case to

isolate the gear case in the event of seal failure and prevent sludge from entering the

timing gear box. The open area shall also allow for physical, visual inspection and/or

adjustment of the mechanical seal. Pumps without an open area (minimum 5.5”)

between the rotor case and gear case are not acceptable. An oil-filled seal chamber

is not acceptable. The open area shall also be able to accommodate a packing gland

arrangement, with no modifications to the pump, should the plant decide to change

to a packed gland in the future. Pumps without the capability of being retrofitted with

either packing or mechanical seals shall not be acceptable.

6. The rotor case surface located behind the rotors shall be fitted with removable wear

plates, enabling their removal without disconnection of the pump from the piping.

7. The rotor case shall be capable of being retrofitted with either a mechanical seal

(single or double) or packing should the application change. This shall be

accomplished without any modifications to the rotor case. Pumps without the

capability of being retrofitted with either packing or mechanical seals (single or

double) shall not be acceptable.

8. Rotor cases incorporating multiple piece designs which includes separate bolted on

fabricated flanges will not be acceptable.

B. Radial Wearplates




11385 - 9

C. The peripheral surface of the rotor case shall be fitted with removable ASTM A743

(CD4MCU) hardened stainless steel radial wearplates to permit the restoration of the

rotor case in the eventuality of worn surfaces without replacing the whole case. The

radial wearplates shall be retained through a series of stainless steel socket-head cap

screws located at the exterior corners of the rotor case. The securing screws for the

radial wearplates shall not protrude into the wearing surface of the wearplates to prevent

premature grooving of the rotors. Other wearplate securing methods such as those with

the screw heads touching or exposed to the rotors or with unprotected threads or with

screw heads/attachment hardware protruding in the flow of the pumped liquids are not

acceptedRear Wearplates:

D. The rear surfaces of the rotor case body shall be lined with a pair of ASTM A240 (Duplex

2205) stainless steel wearplates. These wearplates shall incorporate fiber-cutting

grooves that prevent the accumulation of fibers behind the rotors. The wearplates shall

be secured with stainless steel hex screws through the rear of the rotor case. The rear

wearplates shall be retained from the rear in a tapered recess boss. The securing screws

for the rear wearplates shall not protrude into the wearing surface of the wearplates to

prevent premature grooving of the rotors. Other wearplate securing methods such as

those with the screw heads touching or exposed to the rotors or with unprotected threads

or with screw heads/attachment hardware protruding in the flow of the pumped liquids

are not accepted. Wearplates shall have no mounting holes on the rotor mating

side.Front Cover:

1. The front cover shall be reversible, hinged open and constructed of ASTM A240

(Duplex 2205) stainless steel and fitted with an oil impregnated bronze pin and

designed to allow for mounting on a stepped seat on either the suction or discharge

flange and to provide unobstructed access to the pump chamber without

disconnecting pipework, glands, or bearing. The cover shall be sealed with a Buna N

0-ring..

2. The reversible front cover shall be rigidly supported by a front hinge constructed of

cast ductile iron. The hinges shall be secured on the front of the front cover, but away

from the swept surface of the rotors (in order to prevent drilled/tapped mounting

holes from accumulating fibers and interfering with the rotors). The hinge mounting

holes must not protrude on the swept surface of the rotors.

E. Rotors:

1. The pump shall be fitted with a pair of intermeshing rotors with a minimum of three

lobes, constructed with ASTM A743 (CD4MCU) hardened stainless steel.

2. The rotors shall be end-mounted on the shafts, held precisely in radial position

through an involute hub design. This shall ensure the positive positioning of the

rotors on the shaft as well as providing precise intermeshing clearances around the

rotors. The rotors shall be axially locked into position by a recessed self centering

taper locking assembly consisting of an internal and external radial expanding ring.

The complete locking assembly shall be protected from the sludge by an O-ring seal

at the rear of the rotor and an O-ring sealed cover completely flush with the front face

of the rotors. The sealing arrangement shall shut out any water, grit or sludge from

touching the shaft or splines, thereby simplifying rotor replacement and preventing

shaft failure. The replacement of the rotors shall not necessitate the adjustment of

the shaft timing gears. Rotors keyed to the shaft, are not acceptable.




11385 - 10

3. The rotors shall be able to be removed and/or replaced individually, and shall be

interchangeable. Rotors that require removal and/or replacement as a set and/or

with special pullers are not allowed.

4. Each shaft shall contain no more than one rotor per shaft. Multiple or “stacked”

rotors per shaft are not allowed.

5. When Elastomer Rotors are used the rotors shall be able to be refurbished when

worn. The pump company shall have an established program for refurbishing the

plants worn rotors back to new condition for a fraction of the price of new rotors.

F. Shafts:

1. The shafts shall be constructed of carbon steel in accordance to AISI 4340 HT and be

appropriately sized and heat treated to ensure a smooth operation and concentric

positioning on the rotors.

2. 2. The motor driven shaft shall be either the upper or lower shaft as determined

by the centerline height of the driver.

3. The shafts shall be non-wetted at all points and sealed from pumped liquids.

G. Seals:

1. Mechanical seals: Each pump shall be supplied with front-loading cartridge type

double mechanical seals and shall be flushed. Each seal shall be removable as a

complete unit, consisting of a seal, shaft sleeve, and seal housing. Mechanical seals

that need to be dissembled/assembled within the pump and/or do not come

completely out of the pump as a completely enclosed and contained unit (cartridge)

are not acceptable. Designs requiring the removal of the rotorcase for seal

replacement will not be acceptable. The seals shall be Model 21 Double Cartridge

with Silicon Carbide faces by John Crane, no equal.

2. The design shall also incorporate accommodations for packing with no design

change to the pump. Should the plant decide to change from mechanical seals to

packing glands at any time in the future, The pump design shall accommodate this

with no design changes or modifications to the pump.

H. Gearcase:

1. The gearcase shall be constructed of cast iron and incorporate a separate oil

reservoir for the bearings of each shaft to ensure adequate lubrication at low running

speed. Pumps that do not have separate oil reservoir for each shaft shall supply a

separate force feed pump and lubrication system. A level sight glass shall be

provided for each reservoir. Sealed expansion chambers shall be used for vent caps

preventing any air transfer to and from the gearbox and shall act as an oil filler cap.

2. The gear case cover shall be fitted with a timing cover plate on the top shaft to permit

adjustment of the rotor timing. The cover plate removal shall expose all of the cap

screws on the torque-locking device. Pipe plugs, caps, or drilled holes, which do not

expose all the cap screws, are not acceptable. Pumps that require the removal of

gearcase oil and the gearcase cover plate to adjust the rotor timing are not

acceptable.




11385 - 11

I. Bearings:

1. Each shaft shall be supported by pre-loaded heavy-duty duplex taper roller bearings

of the anti friction type (four bearing per shaft). Pumps with simplex bearings, ball

bearings, straight roller bearings and/or only two bearings per shaft shall not be

accepted. The positioning of the shafts relative to the gearcase shall be such to

permit removal of one shaft bearing without disturbing the bearings of the opposite

shaft.

2. AFBMA L-10 rating of 50,000 hours under maximum operating conditions.

3. Pump shafts shall be designed to support all operating loads without support from an

outboard bearing. Pumps with outboard bearings will not be allowed.

J. Timing Gears:

1. Timing gears shall be precision type and shall be constructed of hardened AISI 8620

carbon steel and precision ground to AGMA Quality, in order to maintain non-contact

between rotors. The timing gears shall be held with self-centering taper lock

assemblies to maintain optimum alignment with the shaft at all times. Timing gears

keyed to the shaft are not acceptable.

K. Bearing Isolators:

1. Bearing shall be completely protected from water or sludge by grease packed

stainless steel labyrinth bearing isolators providing full protection with the pump

either operating or idle. The gearcase wall adjacent to the rotor case shall be sealed

from water or sludge penetration by a pair of non-wearing stainless steel AISI 316,

grease filled labyrinth-bearing isolators. Bearing isolators shall consist of a statically

mounted shaft retainer with double-groove on the outer face. A labyrinth ring shall be

mounted against the shaft and interlock with the grooves on the retainer. The

retainer shall be fitted with a grease connection nipple allowing grease input to act as

a barrier within the labyrinth. The design shall incorporate a double lip oil seal to

contain the grease oil and provide additional bearing protection. Mechanical or

magnetic seals are not acceptable in this area. The design shall ensure that no water

or dirt enters the gearcase adjacent to the seal housing area, permitting periodic

hose down of any eventual sludge run-off in the gland area.

L. Shaft Sleeves:

1. The shaft sleeves shall be of the O-ring sealed, hooked type design. An O-ring shall be

positioned at the back-end of the sleeve and the front-end shall be compressed by

the elastomeric surface of the rotor. The shaft sleeves shall fully extending to the

labyrinth bearing isolators, thereby leaving no exposed surface of the shaft. The shaft

sleeve shall be constructed from AISI 316 stainless steel. The shaft sleeves shall be

easily removable from the pump without the removal of the rotor case. Pumps that

require removal of the rotor-case are not acceptable.

M. Couplings:

1. Furnish a flexible, forged steel coupling of an approved type for connecting the pump,

reducer and motor. Provide a coupling of proper size to transmit the power required

to drive the pump under all conditions of operation. Coupling design shall account for

inaccuracies of alignment and permit axial adjustment. Coupling construction shall

be such that either connected shaft of a unit may be removed without disturbing

adjustment of the other. Coupling shall be by Falk Wrapflex or equal.

2. OSHA approved guards shall be furnished over all couplings.




11385 - 12

N. Drive Arrangement:

1. Each pump shall be furnished with a gear reducer. Each reducer shall be SEW

Eurodrive compact MC series, foot mounted, or equal by Nord, Radicon or equal.

2. Housing shall be cast iron ASTM A48-76 grade 30.

3. Provide steel helical gears, conforming to AGMA Class 12 with a Rockwell “C”

hardness of not less than 58. The hard finishing of the gear teeth shall be grinding or

skive hob with standard drop forged gear blanks. The momentary overload capacity

shall not exceed 275%.

O. Mounting Plates

1. Rigidly mount each pump along with its associated motor, drive, and appurtenances

on a common Type I baseplate as defined in Section 11002. Pump and drive

assemblies shall be supported on a common concrete equipment pad, as specified.

2. Pump base and support shall be rigidly mounted. Pump and drive assemblies shall

be supported on a common heavy duty fabricated steel baseplate. Factory mount

pump, coupling and motor on a heavy duty common steel base, properly braced to

form a rigid support for the entire unit with machined pads under all equipment feet

and alignment tabs for ease of any future field alignment. Factory-align the units on

the base prior to shipment. Contractor to check alignment after installation and re-

align if necessary.

2.08 EQUIPMENT MOUNTS

A. Mounting Plates: Mounting plates per Section 11002. Mounting plate leveled to 0.005

inch/foot or less.

B. Pump and motor mounted on a common baseplate.

C. Grout Type: cementitious non-shrink grout per Section 03600.

D. Equipment Anchors and sleeves per Detail D/S007.

E. Equipment Anchor Sleeves per Section 11002.

F. Equipment Pad per Detail C/S007.

2.09 MOTOR AND DRIVE UNIT

A. Ensure that electric motors conform to the requirements of paragraph 2.03 Design

Requirements and Section 16222. Ensure that the motors include 120-volt alternating

current space heaters. Motors for adjustable speed pumps must be inverter duty type,

and include a high motor temperature switch.

Provide electric motor manufacturer's standard overhaul instruction for motors 5

horsepower and larger.

B. Drive Unit:

1. Ensure that belts, sheaves, and guards are in accordance with Section 11000.




11385 - 13

2. Ensure that maximum speed reduction ratio for the V-belt is as recommended by the

manufacturer. Design gear motors or gear reducers in accordance with AGMA 6019-E

(Class II) or AGMA 6010-E (Service Factor 1.25).

2.10 ELECTRICAL AND INSTRUMENTATION COMPONENTS

A. FOG Waste Screen Pump Control Panel:

1) The control panel shall include, but not be limited to a variable frequency

drive and associated control and pilot devices.

2) The control panel shall be designed such that basic start stop control and

status indicators are available to all users. Operations set points and controls

shall be protected such that only authorized personnel shall have access

locally or through the plant PLC/SCADA system.

3) All components shall conform to electrical area classifications; non-

conforming components shall not be accepted.

4) The control panel shall provide control power to instrumentation associated

with the FOG Waste Screen Pump.

5) Panel shall include the following components:

a) Enclosure, NEMA 12.

b) UL508A label.

c) Short circuit rating for panel assembly: 35,000 amperes symmetrical at

480V.

d) Disconnect, with Door Interlocked Handle, lockable.

e) AFD as specified in Section 16262.

(1) Pump supplier is responsible for providing the fixed reduction

between the motor and the pump. The reduction ratio must be that

required to operate the pump at its maximum operating speed when

the motor is operating at its nominal rated full speed in accordance

with this specification. Ensure that AFD controls are such that pumps

cannot operate at a speed lower than what corresponds to the

minimum pumping rate as specified within this section.

(2) Rate AFD for full motor torque from 25 percent to full speed.

(3) Provide constant torque drive.

(4) Provide input line reactor.

(5) Manual 10-turn speed pot for each drive operable in the Hand

position only.

f) Control Power Transformer, 480-120VAC w/branch circuit protection.

g) Pilot Lights:

(1) Control power on (white) (one each)

(2) Running (red)

(3) Off (green)

(4) Fault (amber) (common fail)

h) Selector Switch (Motor HOA).

i) Panel Heater, with adjustable thermostat.




11385 - 14

j) Provide run-dry protection by [power monitoring/discharge pressure

monitoring/suction head on the suction side].

k) [Suction pressure monitoring]

(1) [Specify low pressure switch components and action.

(2) Upon achieving a specified head under liquid falling conditions, the

low pressure switch will cause the [plant control system/motor

starter] to initiate a shutdown.

2.11 FINISHES

A. Painting of equipment shall be in accordance with Section 09900.

B. All equipment and fabricated surfaces shall be shop primed and finish coated prior to

shipment from the factory.


A. Factory Testing:

1. Perform manufacturer’s standard test.

2. Factory performance tests will not be required. However, have the manufacturer

guarantee the performance specified under paragraph 2.03 Performance

Requirements.

PART 3 EXECUTION

3.01 EXAMINATION/EQUIPMENT MOUNTING

1. Procedure: Section 11002

2. Position equipment pad and equipment anchors for final placement of equipment

3. Use a bolting template to position equipment anchors

4. Level mounting plates

5. Pour grout bed supporting each mounting plate

6. Eliminate grout voids below mounting plate

7. Tension equipment anchors

8. Provide a completed certificate of proper installation per Section 01756.

3.02 PREPARATION/ALIGNMENT



A. Field Testing:

1. Have the contractor include in the bid all costs for services of testing firms and

design professionals performing these services.

B. Manufacturer Services: Section 01640.




11385 - 15

3.04 SYSTEM STARTUP


B. Preoperational (factory) testing; See paragraph 2.10.

C. System testing:

1. After completion of installation, completely test the pump to ensure compliance with

operating requirements as specified and in accordance with the testing procedures in

Section 01756.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Pre-Engineered Metal Building Structure



13122 - 1

SECTION 13122

PRE-ENGINEERED METAL BUILDING STRUCTURE

PART 1 GENERAL

1.01 DESCRIPTION

A. SCOPE:

1. This section specifies the Pre-Engineered Metal Building System, which includes the

structural steel system primary and secondary members, metal roof system, wall

system, column base plates and anchor bolts, with vapor barrier and accessories,

soffits, (2) one-ton monorail hoists and a single monorail beam as described in this

performance specification and shown on the Drawings.

2. The scope of work for the Contractor shall include the design, supply and installation

of the Pre-Engineered Building System, and includes, but is not limited to: (2) one-ton

monorail hoists, a single monorail beam, support framing and connections; and

column anchor bolts.

3. The pre-engineered metal building is a deferred submittal which shall be provided to

the Building Official for review and approval. Refer to Section 01330.

B. BUILDING DISCRIPTION:

1. One pre-engineered building is to be provided for the Clean Water Services Durham

Wastewater Treatment Facility FOG Tank Retrofit Project.

2. The FOG Waste Screen Facility structure will be a canopy type structure that covers a

FOG waste screen and pump, it will have a frame span of 20’-5” with a length of 27’-

8”. Siding for the FOG waste screen facility structure will be located at the south and

east column lines and extend down 5’-6” below the roof eaves.

1.02 1.02 DESIGN REQUIREMENTS

A. ROOF SNOW LOADS:

Code: OSSC 2019 & ASCE 7-16

Risk Category: III

Ground Snow Load (pg): 10 psf

Exposure: C

Thermal Factor (Ct): 1.2

Importance Factor (Is): 1.1

Flat Roof Snow Load: 22 psf

Drifting: Per ASCE 7

Rain Surcharge Per OSSC

1. All roof structures and building frames shall be adequately designed for the required

snow loads. Due consideration shall be given to drifting and the possible formation

of ice dams resulting in ponding of water on un-insulated roofs.




13122 - 2

2. When considering snow loads, roof live loads should only be reduced by the portion

of the live load attributable to loads that would not occur simultaneously with snow.

The live load allowance for piping, conduit, and lights will be included in the design

calculations.

B. B. WIND LOAD:

1. All structures to be designed to withstand the design wind loads without

consideration of shielding effects by other structures.


Risk Category: III

Basic Wind Speed: 103 mph (3-sec. gust)

Exposure: C

Topographic Factor (Kzt): 1.0

C. SEISMIC LOAD:


Risk Category: III

0.2 sec. Spectral Response, Ss: 0.85 g

1.0 sec. Spectral Response, S1: 0.39 g

Site Class: D

0.2 Sec. Design Spectral Response, SDS: 0.68 g

1.0 Sec. Design Spectral Response, SD1: 0.50 g

Importance Factor: 1.25

Component Importance Factor (Ip): 1.0, except Ip=1.5 for components

identified in Section 13.1.3 of ASCE 7

Seismic Design Category: D




13122 - 3

D. DEAD LOAD:

1. Dead loads used in the calculations shall be the weight of building system

construction, such as framing, roofing, purlins, insulation, accessories, and covering

materials. An additional allowance will also be added for collateral loads listed

below. Purlins to be designed for all concentrated load from suspended mechanical

and electrical equipment, pipes and cable tray as shown on the drawings.

E. COLLATERAL LOAD:

1. Additional imposed loads required by the contract documents other than the weight

of the building system. These added loads include such items as sprinklers,

mechanical and electrical systems. Collateral loads shall be:

Roof: Mechanical system and lighting = 5 psf

F. LIVE LOAD:

Roof live load: 25 psf

Columns: No column live load reduction allowed

G. IMPACT LOAD:

1. All structures to consider impact loads in design of support systems. Use the

following impact load factors unless recommendations of the equipment

manufacturer will cause a more severe load case:

Vertical: 25% of lifted load

Longitudinal: 10% of lifted load

2. Deflections not listed above shall be in accordance with the applicable provisions of

the AISC Steel Design Guide Series 7 – Industrial Buildings: Roofs to Anchor Rods.

H. TEMPERATURE:

1. Include the effects of temperature in design where metal building systems are

exposed to differential climatic conditions. See climatic conditions below for

temperature extremes.

Maximum design temperature: 110 degrees Fahrenheit

Minimum design temperature: 10 degrees Fahrenheit

2. Roof panels in a standing seam roof system shall be free to move in response to the

expansion and contraction forces resulting from a temperature variation. Assembly

to permit movement of components without buckling, failure of joint seals, undue

stress on fasteners or other detrimental effects, when subject to temperature range

specified.

I. LOAD COMBINATIONS:

1. Design metal building systems to withstand the load combinations as specified in the

governing building code. Where the exclusion of live load or impact load would cause

a more severe load condition for the member under investigation, then ignore the

load when evaluating that member.




13122 - 4

J. DEFLECTIONS:

1. Calculations for building deflections shall be performed using only the bare frame

method. Reductions based on engineering judgment using the assumed composite

stiffness of the building envelope shall not be allowed.

2. Deflections for Primary Framing shall be as specified below:

a. Horizontal Drift: H/80, not to exceed 3 inches, where H is the eave height of the

building.

b. Vertical Deflection: Per OSSC limits; L/450 for members supporting a monorail.

3. Deflections for Secondary Framing shall be as specified below:

a. 1. Horizontal Drift: H/360 for load cases that include wind and L/180 for load

cases that include seismic.

b. 2. Vertical Deflection: Per IBC limits.

4. Deflections not listed above shall be in accordance with the applicable provisions of

the AISC Steel Design Guide Series 3 – Serviceability Design Considerations for Steel

Buildings.

K. PRIMARY FRAMING AND ANCHOR BOLTS:

1. The column bases shall be designed as pinned connections. No moments shall be

assumed to be transferred to the foundations.

2. Anchor bolt design, size and arrangements shall be coordinated between the Pre-

Engineered Building Manufacturer and the foundation design as shown on the

Drawings. Anchor bolt arrangements shall meet the minimum bolt spacing

requirements per the ACI. Anchor bolt design is by the contractor and shall meet the

requirements as per ACI 318-14, Chapter 17.

L. SECONDARY FRAMING:

1. Purlins at the standing seam roofs shall be braced in accordance with FMRC

standards when a standing seam roofing is used. Where an accepted FMRC design

does not exist, the design of the roof purlins and associated bracing shall meet or

exceed requirements in the latest version of the American Iron and Steel Institute

(AISI) “North American Specification for the Design of Cold-Formed Steel Structural

Members”.

M. METAL PANELS

1. Paneling system shall be designed to support design snow load, wind loads, and live

loads. Panels shall be designed to support a 200 pound load over a 2 foot square

area centered between purlins without exceeding a panel deflection to span ratio of

1/180.

2. Wall paneling system shall be designed to support design wind loads.


A. REFERENCE STANDARDS








13122 - 5





date of the Agreement if there were not Bids). If referenced documents have been







later date discontinued or replaced.

Reference Title

IBC 2018 International Building Code (IBC) with Kitsap County and Washington State

Building Code amendments.

ASCE 7-16 Minimum Design Loads for Buildings and Other Structures

ACI 318-14 Building Code Requirements for Structural Concrete and Commentary

AISI S100 North American Specification for the Design of Cold-Formed Steel Structural

Members

AISC 360 American Institute of Steel Construction Manual of Steel Construction

AISI American Iron and Steel Institute

MBMA Metal Building Manufacturer’s Association

OSHA Occupational Safety Health Association

AWS D1.1 American Welding Society

ASTM A36/A572 Carbon Structural Steel

ASTM A123 Zinc (Hot-Dip Galvanized) Coating on Iron and Steel Products

ASTM A307 Carbon Steel Bolts and Studs, 60 ksi Tensile

ASTM A325 Structural Bolts, Steel, Heat-Treated, 120/105 ksi Tensile

ASTM A500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds

and Shapes

ASTM A525 Steel Sheet, Zinc-coated (Galvanized) by the Hot-Dip Process, General

Requirements

ASTM A529 High-Strength Carbon Manganese Steel of Structural Quality ASTM A572 High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A792 Steel Sheet, 55% Aluminum Zinc Alloy-Coated by the Hot-Dip Process

ASTM A992 Structural Steel Shapes

ASTM A1011 Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural,

High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and

Ultra-High Strength

ASTM D2244 Calculation of Color Tolerances and Color Differences from Instrumentally

Measured Color Coordinates

ASTM D4214 Test Methods for Evaluating the Degree of Chalking of Exterior Paint Films

ASTM E936-98 Standard Practice for Roof System Assemblies Employing Steel Deck, Preformed

Roof Insulation, and Bituminous Built-Up Roofing

FS HH-I-521F Insulation Blankets, Thermal, Mineral Fiber

ASTM 2201-99 Standard Practice for Preparation of Zinc-Coated and Zinc-Alloy-Coated Steel

Panels for Testing Paint and Related Coating Products

AISC Design Guide 3 Serviceability Design Considerations for Steel Buildings

AISC Design Guide 7 Industrial Buildings: Roofs to Anchor Rods

http://www.astm.org/Standards/A1011.htm



http://www.astm.org/Standards/E936.htm

http://www.astm.org/Standards/E936.htm

http://www.astm.org/Standards/D2201.htm

http://www.astm.org/Standards/D2201.htm




13122 - 6

3. All structural mill sections or welded-up plate sections shall be designed in

accordance with Chapter 22 of the International Building Code (IBC).

4. All cold-formed steel structural members shall be designed in accordance with AISI

“North American Specification for the Design of Cold-Formed Steel Structural

Members”.

5. All components of the wall and roof paneling system shall be designed in accordance

with AISI “Specification for the Design of Cold-Formed Steel Structural Members”.

6. Workmanship, detailing of connections, fabrication and erection shall conform to

American Institute of Steel Construction (AISC) Manual of Steel Construction.

B. QUALIFICATION REQUIREMENTS

1. QUALIFICATIONS OF BUILDING MANUFACTURER: The minimum requirements for

qualification shall be 5 years of experience in the design and fabrication of pre-

engineered metal buildings and evidence of satisfactory completion of 5 projects

comparable in scope to the work specified herein.

a. Manufacturer shall participate in the AISC Certification program and be

designated and AISC Certified Plant, Category MB (Metal Building Systems).

b. Submit qualifications and experience with bid. Afterward, the Contractor shall

not substitute a different manufacturer.

2. QUALIFICATIONS OF BUILDING ERECTOR: The Erector shall be familiar with

Manufacturer’s pre-engineered metal building systems, standard and /or custom

concepts and shall be required to perform all work in a manner that will best

incorporate modern materials and methods.

a. Erection shall be performed by qualified erector using proper tools and

equipment in accordance with manufacturer’s recommendations.

3. QUALIFICATIONS OF WORKMAN: The Erector shall provide at least one person who

shall be present at all times during execution of work and who shall be thoroughly

familiar with pre-engineered metal building concept and the requirements thereof,

and who shall direct all work performed.

a. All workers employed by the Erector shall be skilled in performing tasks related to

pre-engineered metal buildings.

b. All welders shall be qualified as prescribed by AWS.

C. DELIVERY, STORAGE & HANDLING

1. The metal building manufacturer and their installation contractor are responsible for

the delivery, storage and handling of all materials.

2. Materials shall be delivered in a dry and undamaged condition and stored out of

contact with the ground. Materials other than framing and structural members shall

be covered with weather tight covering and kept dry. Storage accommodations for

roof and wall covering shall provide good air circulation and protection from surface

staining.

D. WARRANTY

1. The Manufacture shall provide the following additional warranties-guarantees for the

pre-engineered building.

a. A one (1) year workmanship guarantee against failures caused by faulty erection.

b. A two (2) year materials and workmanship guarantee against failures.




13122 - 7

c. Manufacturer’s written weather tightness warranty for ten (10) years against

leaks in roof panels arising out of or caused by ordinary wear and tear under

normal weather and atmospheric conditions.

d. Manufacturer’s paint film written warranty for 20 years against chipping,

cracking, peeling, chalking, and fading of the coating on painted wall panels,

painted roof panels and soffit panels.

1) Chalking shall not exceed #8 per ASTM D4214.

2) Fading shall be 5 NBS units or less per ASTM D2244.

2. Warranty period shall be from the date of Substantial Completion.

1.04 SUBMITTALS

A. Prior to release for manufacture of the building, the following items shall be submitted in

accordance with Section 01330:

1. Pre-engineered building design and drawings:

a. Provide drawings, prepared and sealed by a Professional Engineer registered in

the State of Oregon. Drawings shall include the following:

1) General arrangement plans and elevations.

2) Primary and secondary framing systems including member sizes and

connection details.

3) Monorail beam, including member sizes and connection details to structural

framing.

4) Location, size, and connection details of diagonal bracing.

5) Siding details, roofing details and roof drainage system details.

b. Provide design calculations of the pre-engineered building, prepared and sealed

by a Professional Engineer registered in the State of Oregon.

c. Letter of Design Certification prepared and sealed by a Professional Engineer

registered in the state of Oregon confirming responsibility for the design and

attesting that the design prepared meets the performance criteria required by the

Contract Documents, the requirements of governing authorities having

jurisdiction at the Site, and conforms to prevailing standards of practice. Letter of

Design Certification shall include the following:

1) Design Loads including dead load, roof live load, collateral loads, roof snow

load, deflection, wind loads/speeds and exposure, design spectral response

accelerations at short and 1-second periods (SDS & SD1), seismic importance

factor (Ie), response modification factor (R), seismic response coefficient (Cs),

and auxiliary loads, such as loading superimposed on the system by erection

equipment.

2) Verification that the metal roofing system is Factory Mutual approved for the

Factory Mutual Rating required at the site. Metal Building supplier shall

calculate the Factory Mutual Rating required in accordance with FM Global

Property Loss Prevention Data Sheet 1-28, latest revision, using the Basic

Wind Speed and Exposure information in this Section.




13122 - 8

d. Product Data: Submit manufacturer's product information, specifications, and

installation instructions for building components, and accessories.

e. Shop Drawings: Submit complete erection drawings showing roof framing,

transverse cross sections, covering and trim details, and accessory installation

details to clearly indicate proper assembly of building components.

2. Anchor Bolt Design and Drawings:

a. Provide drawings that include anchor bolt size, material, orientation and location,

building column base plate details and all base attachments where required.

b. Provide anchor bolt calculations stamped by a Professional Engineer registered in

the State Oregon. Drawings shall include the unfactored building column loads

imposed on foundations. Unfactored column loads are to be separately shown

for dead load, live load, snow load, and the governing lateral load (earthquake or

wind).

3. Color chart identifying color that matches existing building colors at the treatment

plant (Hemlock Green).

4. Two of each of the following samples will be used as basis for evaluating quality of

finished roof and wall systems and selection of colors

a. Twelve inches long by actual width of roofing, liner panel and siding panels, with

specified finishes.

b. Fasteners for application of roofing, siding and soffit panels.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. The pre-engineered metal building shall be engineered and manufactured by Allied

Buildings, Butler Manufacturing, Star Building Systems, Varco-Pruden Buildings, Great

Western Buildings, or equal. Allied Buildings was used as the basis of design.

2.02 MATERIALS

A. All components and parts shall be clearly marked. Erection drawings shall be supplied

for identification and assembly of the parts.

B. FRAMING

1. PRIMARY FRAMING:

a. Rigid Frames: Frames shall consist of welded-up plate section or hot-rolled wide

flange columns and beams complete with necessary splice plates for bolted field

assembly.

b. All bolts for field assembly of frame members shall be galvanized A-325, Type 1,

high strength bolts.

c. End Walls: Rigid Moment Frames shall be used at end walls.

d. Anchor Bolts: Contractor shall design and supply the anchor bolts. The anchor

bolt design, size and arrangement shall be coordinated between the Metal

Building Manufacturing Company and the foundation design as shown on the

drawings.

1) All anchor bolts shall be galvanized and in accordance with specification

section 05502.




13122 - 9

2. SECONDARY STRUCTURAL MEMBERS:

a. Roof Purlins and Wall Girders: Purlins and girders shall be galvanized (G-60) per

ASTM A653. Purlins and girders shall be "Z" shaped, precision roll formed. The

interior flange of girts shall be turned down to avoid forming a pocket for dust

and debris.

b. Eave Struts: Eave Struts shall be 8", 9-1/2", or 11" deep "C" sections.

c. Bracing: Bracing be located at perimeter walls in locations shown on the contract

drawings. Interior bracing is not allowed (i.e. vertical bracing to interior columns).

1) Diagonal bracing shall be hot-rolled rod and attached to columns and roof

beams. Double back-to-back angle bracing is not allowed in this corrosive

environment.

2) Flange braces, purlin braces, etc., when required, shall be cold formed.

3. TRIMS AND FLASHING:

a. The system shall be complete with integrated pre-engineered trims and flashings

to accommodate reasonable variances in tolerances and thermal movement.

Minor flashings may be field fabricated.

b. Rake flashing, corner trim, eave trim, and all other necessary trim shall be 26

gage G90 zinc-coated, pre-painted, color to match wall panels.

c. Pipe flashing shall be of one piece construction and fabricated from an EPDM

membrane and shall have an aluminum base formed to roof panel profile.

d. Trims and flashings shall be painted with the metal panel coating system listed

below and shall match the color of the wall or roof panels.

C. CLOSURES AND SEALANTS

1. Preformed closed cell non-shrinking, laminated polyethylene closures along the eave,

ridge, and rake for weather tightness.

2. 20 gage metal closures at standing seam roof panels, color coordinated with the

same coating system as roof panels.

3. Sealant for end laps, roof flashing laps, ridges, and eave shall be tape mastic, 100%

solid ethylene propylene copolymer tape.

4. Sealant for roof accessories shall be polyurethane.

D. COATING OF STRUCTURAL MEMBERS:

1. Primary structural steel framing shall be galvanized per ASTM A123. Secondary steel,

such as purlins and girts, shall be hot-dipped galvanized (G60) per ASTM A653. Field

touch up shall be with Galvicon 1-4853 by Southern Coatings or equal.

2. Prior to galvanizing, steel shall be cleaned of loose rust, loose mill scale, dirt and

other foreign material.

3. COATING OF PANELS

a. The metal panel coating system for the exterior side of roof and wall panels shall

be a full strength, 70% Kynar 500®/Hylar 5000(TM) fluoropolymer coating,

Flurothane IV system, or approved equal. Color shall be Hemlock Green to match

existing color scheme used for other structures at the treatment plant.

b. The interior side of the roof panels, wall panels and trim material shall be coated

with primer and a universal off-white polyester paint coat.




13122 - 10

PART 3 EXECUTION

3.01 EXAMINATION

A. SURVEYS:

1. Check lines and elevations of concrete bearing surfaces. Confirm locations of anchor

bolts and similar devices before metal building erection proceeds. Report

discrepancies immediately to the Owner. Do not proceed with erection until

corrections have been made, or until compensating adjustments to the steelwork

have been agreed upon.

3.02 ERECTION

A. Erect the work in accordance with Specifications, Drawings, and Manufacturer's

directions.

B. Conform to configurations and connections indicated on reviewed and accepted Shop

and Erection Drawings.

C. Temporary shoring and bracing: Provide members with connections of sufficient strength

to bear imposed loads. Remove temporary members and connections when permanent

members are in place and final connections have been made. Provide temporary guy

lines to achieve proper alignment of structures as erection proceeds.

D. Accurately position and assemble structural framing to lines and members of framing

system prior to permanent fastening.

E. Install metal panels, fasteners, trim, louvers, and related items in conformance with

approved drawings and requirements of manufacturers. Protect installed panels and

structures from abuse by other trades.

F. Erector shall not make any field modifications to any structural member except as

authorized and/or specified by manufacturer in writing, with a copy to the Owner.

3.03 REPAIR/RESTORATION

A. Replace damaged panels and other components of work that cannot be repaired by

finish touch-up or similar minor repair.

B. Touch-up coatings: Immediately after erection, clean field welds, bolted connections, and

areas where coating is abraded. Apply coating to exposed areas using same material as

used for shop coating.




13122 - 11


A. The Construction Manager will inspect and indicate if work is in conformance with

specifications. This inspection will include products, erection, welding, grouting and

similar construction. The Construction Manager will verify that the work has been

performed in accordance with AISC and this specification.

B. Maximum deviations from plumb, level, and alignment are not to exceed AISC

specifications, and tolerances specified in this section.

C. Defective Work: Promptly remove and replace materials and fabricated components that

do not comply. Furnish, perform, and install to specified requirements.

3.05 CLEANING

A. Upon completion of the services, the metal building manufacturer and their installation

contractor shall remove all excess materials, tools, scaffolds and rubbish which has

accumulated on the premises and leave same in a clean and satisfactory condition.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Shop-Fabricated Multi-Column Hopper Bottom Welded Stainless

Steel FOG Storage Tanks



13201 - 1

SECTION 13201

SHOP-FABRICATED MULTI-COLUMN HOPPER-BOTTOM WELDED

STAINLESS STEEL FOG STORAGE TANKS

GENERAL

1.01 DESCRIPTION

A. SCOPE:

1. The work to be performed under this section consists of the furnishing of all

materials, tools, equipment, labor and incidentals necessary for the design,

manufacture, delivery, erection, cleaning, and testing of multi-column elevated

welded stainless steel tanks and accessories for the storage of fats, oils, and grease

(FOG).

B. TANK DESIGN:

1. Tank dimensions shall be as specified. Tank shall be a shop-fabricated multi-column

supported hopper-bottom welded stainless steel tank. Tanks that are partially shop-

fabricated and field assembled will be allowed as an alternative. It shall have a self-

supported conical roof. Design of the tank shall comply with API 620 Twelfth Edition

(hereafter, API 620) including Annex S, API 650 Twelfth Edition annex J, and as

herein modified. The effects of an oscillating liquid surface in the tank shall also be

taken into account. The drawings of the stainless steel tank are intended to define

general dimensional requirements and tank configuration. Inlet, outlet, and overflow

configuration shall be as specified. The Supplier shall design the tank and all

required structural supports, anchors, and stiffeners in accordance with the

requirements contained herein. Design calculations shall be provided in sufficient

detail to indicate the procedures used, stamped and signed by a Professional or

Structural Engineer licensed to practice in the State of Oregon.

2. Reference drawing M102 for nozzle connection locations and sizes.

C. DESIGN CRITERIA:

Tank Design Item Value

Nominal usable capacity 29,000 gallons

Diameter 16 ft,6 in.

Height of cylindrical wall 19 ft, 0 in.

Height of tank 30 ft, 0 in.

Hopper slope 30 degrees () from horizontal

Freeboard, feet 1 ft

Roof live load 20 pounds per square feet (psf)

Ground snow load 10 psf

Platform Live Load 60 psf

Basic wind speed 103 mph (LRFD)

Exposure category C

Design Pressure 1 psi

Design Vacuum 1 in. w.c.





13201 - 2

Tank Design Item Value

Stored Liquid Specific Gravity 1.0

Stored Liquid Fats, Oils, and Grease

Winter Design Temperature 10° Fahrenheit (F)

Note: Roof shall be a self-supported cone roof, with a slope of 2" in 12".

D. SEISMIC DESIGN:

1. GENERAL: The Supplier shall design the tank, and accessories in conformance with

API 620, Annex L, ASCE 7-16, and modified as specified herein with the following

data to determine the minimum strength requirements of the tank for seismic

design.

a. Seismic Design Category: D

b. Seismic Use Group: II

c. Seismic Importance Factor, IE = 1.25

d. Site Class: D

e. SDS =0.678 g; SD1 = 0.497 g

f. Vertical acceleration: Per API 620 annex L and ASCE 7-16

g. Freeboard: One foot below top of tank wall.

h. Combine hoop stresses by root mean square.

i. Pressure stability: Do not consider for seismic loading.

j. Roof seismic design: Include vertical acceleration as required by ASCE 7-16

2. HYDRODYNAMIC SEISMIC HOOP TENSION: The impulsive hoop force in pounds per

inch shall be calculated in conformance with API 620.

1.02 REFERENCES





those of the listed documents, the requirements of this section shall prevail.

B. Unless otherwise specified, references to documents shall mean the documents in effect

at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the


the issuing organization, references to those documents shall mean the replacement




shall mean the specific document version associated with that date, regardless of

whether the document has been superseded by a version with a later date, discontinued

or replaced.

Reference Title

AISI Pocketbook of AISI Standard Steels

ASTM A240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate,

Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A276 Standard Specification for Stainless Steel Bars and Shapes





13201 - 3

Reference Title

ASCE 7-16 Minimum Design Loads and Associated Criteria for Buildings and Other Structures

OSSC 2019 Oregon Structural Specialty Code

API 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks

UL 96A Installation Requirements for Lightning Protection Systems, Ninth Edition

1.03 SUBMITTALS

A. The following information shall be provided in accordance with Section 01330:




requested deviations from specification requirements. Check marks (✓) shall denote

full compliance with a paragraph as a whole. If deviations from the specifications are

indicated, and therefore requested by the Supplier, each deviation shall be


paragraph, referenced to a detailed written explanation of the reasons for requesting

the deviation. The remaining portions of the paragraph not underlined will signify

compliance on the part of the Supplier with the specifications. Failure to include a

copy of the marked-up specification sections, along with justification(s) for any

requested deviations to the specification requirements, with the submittal shall be

sufficient cause for rejection of the entire submittal with no further consideration.

2. Dimensional drawings.

3. Anchor bolt placement plans.

4. Accessory list with fabrication detail.

5. Catalog cuts, and descriptions of standard manufactured items.

6. Procedure for cleaning of tanks and components.

7. Operations and maintenance data for all standard manufacturer items.

8. Structural calculations of tanks, tank anchorage and tank supports, platforms,

guardrails, and pipe supports stamped and signed by a Professional Structural

Engineer licensed to practice in the State of Oregon.

PRODUCTS

2.01 GENERAL

A. Unless otherwise specified, materials and construction shall conform to API 620.

Stainless steel plates shall conform to ASTM A240 type 316 and structural shapes shall

conform to ASTM A276 type 316. All tank materials and accessories shall be Type 316

stainless steel unless other otherwise specified.

2.02 SHELL

A. Shell plates shall be cold rolled to the tank radius. Horizontal and vertical joints shall be

butt welded on each side with full penetration. If structural bracing of the shell is

required, these members shall only be placed on the inside of the shell. Shell plates shall

include all vertical plates.





13201 - 4

2.03 ROOF, RAFTERS

A. The tank roof shall be conical.

2.04 ACCESSORIES

A. MANHOLES AND HANDHOLES:

1. Shell manholes shall be 36 inches in diameter clear opening, inward-swing style, and

shall be hinged to the shell. Manholes shall be gasketed and watertight, with

handwheel operators. A stainless steel manway sleeve extension shall protrude

radially outward from the tank shell, and be supplied with a hinged, 10-gauge 316

stainless steel security cover. Handwheel stem shall extend beyond the security

cover and include a lockout point. Gasket material shall be Viton. Shell manways

shall be Chase Manways Model CM-2 with security cover.

2. Roof manholes shall be 24 inches in diameter clear opening, with a 316 stainless

steel dished head. The dished head shall be out-swing style, with locking hinge, and

toggle clamps that require a wrench to loosen. Manholes shall be gasketed and

watertight. Gasket material shall be Viton. Roof manways shall be Chase Manways

Model CM-12.

B. PIPE CONNECTIONS:

1. All pipe and pipe connections shall be constructed to the limits specified. Pipe

connections shall be provided in the tank shell per API 620, Section 5 and as

specified. Nozzles assemblies shall be made of schedule 80 pipe sections.

Penetrations of shell shall not be less than 12 inches clear above bottom. Inlet and

outlet nozzles shall be sized for clear inside diameters. Refer to Drawing M102 for

connection sizes and locations. Gasket material shall be Viton.

2. Contractor shall verify size of existing pipe mount for level instruments 715LIT6401

and 715LIT6402 on roof of existing tanks. Connection size listed for nozzle numbers

4 and 13 in nozzle schedule on drawing M102 shall be the same as existing.

C. VENT:

1. A flanged tank connection shall be provided on the tank roof for venting. The

connection shall be configured per API 620 Section 5, with a raised flange face

extending not less than 12 inches above the roof. Pressure/vacuum relief valve to be

provided by others.

D. LIGHTNING PROTECTION SYSTEMS:

1. Supplier shall supply grounding lugs complying to NFPA 780 and UL 96A. Design of

lightning protection system shall be provided by others.

E. PLATFORMS, LADDERS, GUARDRAILS

1. An intermediate level access platform, roof access platform, ladders, and guardrails

shall be provided between the two tanks. Access to the tank manways and external

tank ladders shall be from the platform. Platform shall be equipped with guardrails

and toe board. See tank drawings for approximate platform sizes and configurations.

The platforms, ladders and guardrails shall be built of 304L Stainless Steel.

Platforms, ladders, and guardrails rails shall be designed to meet OSHA requirements

for safety and fall protection.





13201 - 5

2. The tanks shall have external ladder(s) meeting the requirements of OSHA 1910

Subpart D Walking-Working Surfaces as shown on the tank drawings. The external

ladder shall be provided with a Safe-T-Climb as manufactured by Miller Fall

Protection or equal and shall conform to the requirements of OSHA Standard Section

1910.28. Ladder rungs shall have a non-slip surface.

3. Each platform ladderway entrance shall be equipped with a self-closing gate as

required in OSHA Standard 1910.28

F. ANCHOR BOLTS

1. Anchor bolts for tanks shall be designed by the Supplier to include tank operational

loads combined with seismic and wind forces. Design criteria provided in paragraphs

13201-1.01C and 13201-1.01D.

G. INSULATION

1. Insulate and clad tank in accordance with the requirements of Section 15250.

H. PIPE SUPPORTS

1. Design pipe supports on tank shell and legs for 6” FOG and 6” FA piping as indicated

on mechanical drawings. Supports shall be designed to accommodate thermal and

seismic movement of tanks and piping systems.

2. Design internal supports for 6” FOG piping inside of each tank.

2.05 PRODUCT DATA


1. Structural calculations of the tanks, platform, anchors, and accessory items as

specified in paragraph 13201-1.01 B.

2. Welding data tabulation and details of welded joints.

3. Erection drawings.

4. Mill test reports of all steel materials with a certification of which ASTM or other API

620 required specification each meets.

5. Report of initial radiographs and evaluation for each weld as specified in paragraph

13201-3.02 A.

6. Report certifying the inspection per Section 7, API 620 at the conclusion of the work.

7. Certificate of compliance with API 620.

EXECUTION

3.01 CONSTRUCTION

A. GENERAL:

1. Unless otherwise specified, construction shall conform to API 620 including Annexes

L and S.

B. WELDING:

1. Unless otherwise specified, all welding shall comply with API 620, Section 6 and

Annex S.





13201 - 6

2. Manufacturer-certified qualification records of the welders employed for fabrication

shall be maintained by the Manufacturer and shall be accessible to the inspector.

The record for each welder shall indicate:

a. Date and result of qualification test.

b. Supplier conducting tests.

c. Identifying mark of welder.

3. All butt joints shall be provided with complete joint penetration welds.

3.02 WELD TESTING

A. SPOT RADIOGRAPHS:

1. Spot radiograph shall be per requirements of API 620. During fabrication of the tank

shell, spot radiographs in the first 10 feet of joint welded by each welder shall be

obtained and evaluated. The radiographs and the evaluation shall be made available

to the Purchaser’s Inspector.

2. A spot radiograph in each 100 feet of shell weld subject to primary stress, and in

each 200 feet of shell weld subject to secondary stress, shall be obtained and

evaluated. A record of the extent of repair of defective welds and the spot

radiographs of repaired joints shall be maintained for review by the Purchaser’s

Inspector and included in the report (per API 620, Section 7) at job conclusion. After

acceptance of the structure, the radiographs or sectional segments shall become the

property of the Owner.

3.03 HYDROSTATIC TESTING

A. After tank fabrication has been completed, the tank shall be hydrostatically tested by

filling it with test water conforming the quality requirements of API 620. Any leaks shall

be repaired, and the structure made watertight. No repair work will be done on any point

unless the water level in the tank is at least two feet below the joint being repaired.

3.04 TEMPORARY CLOSURE OF TANK OPENINGS

A. Tank openings that are not fitted with valves, hatches, or manhole covers at the

completion of erection shall be provided with temporary covers of metal, 10-gage

minimum, or plywood, concrete-form quality, cut to fit. Covers shall be installed using

three or more bolts. The covers are intended to exclude dust, animals, and intruders

before and after acid washing.

3.05 SAFETY

A. The Supplier shall strictly comply with all applicable statutes, regulations, orders, rules,

requirements and standards of all governmental authorities having jurisdiction with

respect to the project, including without limitation, federal, state, and local OSHA and

health regulations as well as the latest professional practices.

B. The Supplier shall, at its own expense, protect its employees and other persons from risk

of injury, bodily harm, or death arising out of or in any way connected with work

performed.





13201 - 7

C. For field assembled tanks, prior to commencing work, all Supplier personnel on the

jobsite will have a minimum 10 hours of OSHA safety training or equivalent training

within the previous year.

3.06 CLEANING

A. The tank shall be cleaned per ASTM A380 and API 620 section S.4.5. Passivation

performed per API 620 section S.4.8 using nitric or citric acid.

3.07 PERFORMANCE GUARANTEE

A. A warranty as to workmanship, material, and satisfactory mechanical functioning for

a period of 12 months after the equipment is placed in service is be furnished in writing

with quotation.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Monorail Hoists



14611 - 1

SECTION 14611

MONORAIL HOISTS

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies a monorail system complete with army-type, integrated trolley

hoist, for installation at the Brown Grease Receiving Facility 715 to remove the

rotating assembly of the FOG drum screen, 715SCR6415. Two trolley hoists shall be

installed on a single monorail beam, as depicted on the contract drawings.

B. Type:

1. The unit shall be underhung, single girder monorail. Hoists shall be of the heavy-duty,

load-chain type with manually driven trolley.

2. The trolleys shall be four wheel type with tracks and appurtenances in accordance

with the drawings, and as specified herein.

3. The trolleys shall be manual-geared type.

C. Equipment List:

1. Equipment numbers are as follows:

Item Equipment No.

FOG Screen Monorail Hoist 1 715HOIST6401

FOG Screen Monorail Hoist 2 715HOIST6402


A. Section 13122 – Pre-Engineered Metal Building Structure


A. References:


















14611 - 2


later date, discontinued or replaced.

Reference Title

ASME B30.16 Overhead Underhund and Stationary Hoists

CMAA Crane Manufacturer’s Association of America

HMI Hoist Manufacturer’s Institute

3. All equipment furnished under this section shall comply in all respects with the

requirements of OSHA, the standards of the Crane Manufacturer’s Association of

America (CMAA), the Hoist Manufacturer’s Institute (HMI), and ASME B30.16

Overhead Underhung and Stationary Hoists.

B. Manufacturer’s Qualifications:

1. The monorail and hoist manufacturer shall be one who is regularly engaged in the

business of designing, building, and repairing monorail and hoists of the type

specified in this section. All monorail components and appurtenances furnished for

this contract shall be designed, coordinated and supplied by a single manufacturer.

C. Performance and Design Requirements:

1. All equipment provided under this section shall be suitable for Class-A, L4, N1 of

service as defined by CMAA standards with the heavy-duty hoist suspended from its

trolley.

2. Monorail beams, complete with connections to the structural support systems,

splices and runway stops, shall be furnished by the crane manufacturer. Monorail

beam shall be designed by a registered civil or structural engineer in accordance with

the hoist manufacturer's recommendations. Load bearing connections shall be

provided at each beam or girder and where necessary to limit deflection to less than

1/450 of span.

3. Load carrying parts, except structural members and hoisting ropes, shall be designed

so that the calculated static stress in the material, based on rated bond, shall not

exceed 20 percent of the assumed ultimate strength of the material. Structural

members shall be designed in accordance with the latest edition of the CMAA

specifications. The rated capacity load plus the weight of the bottom block divided by

the number of parts of hoisting rope shall not exceed 20 percent of the published

breaking strength of the rope.

D. Operating Requirements:

1. Operating requirements shall be as follows:

Parameter 715HOIST6401a 715HOIST6402a

Capacity, tons 1 1

Vertical lift, feet 15 15

Maximum chain pull, lbs. 70 70

Bottom of monorail beam flange, min,

EL.

173.58’ 173.58’




14611 - 3

Parameter 715HOIST6401a 715HOIST6402a

High hook level above grade,

minimum, EL.

172.58’ 172.58’

Maximum hoist headroom, inches 12 12

Environment Outdoors Outdoors

Hoist and trolley Controller Type Manual Manual

Notes:

aBoth hoists will be installed and operate on a single monorail beam.

2. Hook approach distances and high hook position shall be as shown on the drawings.

The Contractor is advised to examine the drawings for interferences and obstructions

which might impose additional limitations upon the equipment.

E. Unit Responsibility:

1. The Contractor shall assign unit responsibility, as specified in Section 11000, to Pre-

Engineered Metal Building (PEMB) manufacturer specified in Section 13122 for all

equipment specified in this section.

1.04 SUBMITTALS

A. The Contractor shall provide the following submittals:




requested deviations from specification requirements. A check mark (✓) shall denote

full compliance with a paragraph as a whole. If deviations from the specifications are

indicated, and therefore requested by the Contractor, each deviation shall be


paragraph, referenced to a detailed written explanation of the reasons for requesting

the deviation. The Owner shall be the final authority for determining acceptability of

requested deviations. The remaining portions of the paragraph not underlined will

signify compliance on the part of the Contractor with the specifications. Failure to

include a copy of the marked-up specification sections, along with justification(s) for

any requested deviations to the specification requirements, with the submittal shall

be sufficient cause for rejection of the entire submittal with no further consideration..

2. A copy of the contract document control diagrams and process and instrumentation

diagrams relating to the submitted equipment, with addendum updates that apply to

the equipment in this section, marked to show specific changes necessary for the

equipment proposed in the submittal. If no changes are required, the drawing or

drawings shall be marked “No Changes Required.” Failure to include copies of the

relevant drawings with the submittal shall be cause for rejection of the entire

submittal with no further review.

3. Completed Certificate of Unit Responsibility attesting that the Contractor has

assigned, and that the manufacturer accepts, unit responsibility in accordance with

the requirements of this section and Section 11000-1.02 Unit Responsibility. No

other submittal material will be reviewed until the certificate has been received and

found to be in conformance with these requirements.

4. Manufacturer's catalog data confirming rated capacity, equipment speeds,

horsepower electrical requirements, and component sizes and dimensions.

5. Operations and maintenance information as specified in Section 01782.




14611 - 4

6. Anchor bolt calculations in accordance with Section 05502.

7. Seismic calculations stamped and signed by a Structural engineer registered in the

state of Oregon.

1.05 PROJECT/SITE CONDITIONS

A. General:

1. Monorail and hoists shall be installed outdoors at the Brown Grease Receiving

Facility 715 at Clean Water Services Durham. Across all specified conditions, the

equipment shall perform without exceeding the manufacturer's stated tolerances.

B. Seismic:

1. Electrical equipment, supports, and anchorage shall be designed and installed in

accordance with the seismic design requirements specified in Section 01612

PART 2 PRODUCTS

2.01 ACCEPTABLE PRODUCTS

A. Monorail hoist shall be Yale 360 Atex, Columbus McKinnon (CM) Hurricane 360, or

approved equal, modified as necessary to meet the requirements of this section.

2.02 MATERIALS

A. Materials for monorail hoists are specified below.

Component Material

Runway beam Steel, ASTM A36

Bottom tees Manganese steel, 225 Brinell hardness

Trolleys, wheels, hook Steel, ASTM A36

Chains Corrosion Resistant Steel or Stainless Steel

2.03 EQUIPMENT

A. Monorail Beam:

1. Monorail beam shall be specially fabricated beams comprised of top flange, web and

hardened steel bottom tee section, continuously welded to the web, with trolley stops

at both ends.

B. Trolley:

1. Trolley wheels shall be hardened steel, mounted on permanently lubricated

antifriction bearings. The trolleys shall be geared, manual push/pull type and shall be

designed with an integral hoist.

2. Bearings shall be fitted with seals to exclude dust and moisture and shall be pre-

lubricated for life.

3. Trolley shall have protective plates to protect the trolley and trolley wheels from

contact with monorail beam end stops.

4. Trolley design shall allow for equal distribution of load on all four (4) wheels.




14611 - 5

C. Load Chain Hoist:

1. Hoist shall be close headroom, hand chain type. The maximum distance between the

bottom of the monorail beam and the eye of the load hook shall be determined from

paragraph 14611-1.02D.

2. Chain hoists shall be enclosed in tightly sealed housing with machined joints

between housing and covers. Gears shall be spur type with machine shaved teth and

heat treated. The load shall be carried on two sets of gear teeth in each gear. Gear

bearings shall be the oil-lubricated antifriction type, and all bearings shall be

designed for a Class M2 (20,000 hour) bearing life.

3. A floating chain guide which completely surrounds the load chain pocket wheel shall

be provided to ensure proper chain entry regardless of pulling angle.

4. Hook: Construct with sufficient ductility to open noticeably before hook failure. Load

hook shall be equipped with a spring safety latch, free to rotate 360 degrees with

rated load, and positively held in place with locknots, collars, or other devices.

D. Hoist Control

1. Control for up and down motions shall be from pull chain. A positively acting load

brake shall be integral to the hoist assembly.

E. Chain container

1. Canvas chain container shall be furnished with the jib crane system and of the same

manufacturer as the hoist/trolley. Chain container size shall be sufficient for holding

slack chain when lifting hook in highest position.

2.04 PRODUCT DATA

A. The following information shall be provided:

1. Operating and maintenance information in accordance with Section 01782.

2. Factory tested certification.

3. Installation and Instruction Certifications, Sections 01640 and 01756.

PART 3 EXECUTION

3.01 INSTALLATION

A. Manufacturer shall test the equipment in accordance with industry standards and federal

regulations prior to shipment of the equipment. The monorail, trolley, and hoist shall be

completely assembled and no load run tested prior to shipment to the job site. Monorail

hoist shall be disassembled to the least amount possible for shipment. The trolley and

hoist shall be installed at the location shown and in accordance with the manufacturer's

recommendations.

B. The monorail system shall be installed and tested by the Contractor with the assistance

of a factory-trained representative. The installation shall be certified as specified in

Section 01756.




14611 - 6

3.02 TESTING

A. After completion of installation, the monorail hoist, trolley, and hoist shall be completely

tested to ensure compliance with the performance requirements as specified. As a

minimum, testing shall be by operating the equipment through a complete lift and

lowering cycle and through a complete travel of the monorail to determine that the

equipment performs smoothly and safely without failure.

B. Such tests shall be carried out with the hoisting equipment loaded as near to the

specified capacity as possible. Any defects shall be corrected or replaced immediately by

the Contractor and at no expense to the Owner. Final OSHA inspection, load tests, all

other testing, and certification shall be at the Contractor's expense.

3.03 TRAINING

A. The Contractor shall provide the services of a factory-trained manufacturer’s

representative to provide training of the Owner’s personnel in the proper operation and

maintenance of the equipment.

B. Prior to final acceptance, the Contractor shall furnish the Construction Manager with two

copies of the manufacturer’s certifications (see Section 01756). Training shall be

performed in accordance with Section 01640.

3.04 MANUFACTURER’S REPRESENTATIVE

A. The Contractor shall include in his bid all costs associated with providing the services of

the manufacturer’s field representative for checking, aligning testing, placing in

operation, and Owner training.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Piping Systems



150500 - 1

SECTION 15050

PIPING SYSTEMS

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies systems of process piping and general requirements for piping

systems. Detailed specifications for the components listed on the Piping System

Specification Sheets are found in other sections of Division 15. This section shall be

used in conjunction with those sections.

B. Definitions:

1. Pressure terms used in Section 15050 and elsewhere in Division 15 are defined as

follows:

a. Maximum: The greatest continuous pressure at which the piping system

operates.

b. Test: The hydrostatic pressure used to determine system acceptance.


A. References:

















Reference Title

AASHTO M36/M36M

Metallic (Zinc or Aluminum) Coated Corrugated

Steel Culverts and Underdrains

ANSI A13.1 Scheme for the Identification of Piping Systems

ANSI B1.20.1 Pipe Threads, General Purpose (Inch)

ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings Class

25, 125, 250, and 800

ANSI B16.3 Malleable Iron Threaded Fittings Class 150 and

300




150500 - 2

Reference Title

ANSI B16.5 Pipe Flanges and Flanged Fittings

ANSI B16.9 Factory-Made Wrought Steel Buttwelding Fittings

ANSI B16.11 Forged Steel Fittings, Socket Welding and

Threaded

ANSI B16.12 Cast Iron Threaded Drainage Fittings

ANSI B16.22 Wrought Copper and Copper Alloy Solder Joint

Pressure Fittings

ANSI B16.26 Cast Copper Alloy Fittings for Flared Copper Tubes

ANSI B31.1 Power Piping

ANSI B31.3 Chemical Plant and Petroleum Refinery Piping

ASME Section IX Boiler and Pressure Vessel Code; Welding and

Brazing Qualifications

ASTM A47 Malleable Iron Castings

ASTM A53 Pipe, Steel, Black and Hot Dipped, Zinc-Coated

Welded and Seamless

ASTM A74 Cast Iron Soil Pipe and Fittings

ASTM A105/A105M Forgings, Carbon Steel, for Piping Components

ASTM A106 Seamless Carbon Steel Pipe for High-Temperature

Service

ASTM A126 Standard Specification for Gray Iron Castings for

Valves, Flanges, and Pipe Fittings

ASTM A197 Cupola Malleable Iron

ASTM A234/A234M Pipe Fittings of Wrought Carbon Steel and Alloy

Steel for Moderate and Elevated Temperatures

ASTM A312/A312M Seamless and Welded Austenitic Stainless Steel

Pipe

ASTM A403/A403M Wrought Austenitic Stainless Steel Piping Fittings

ASTM A536 Ductile Iron Castings

ASTM A570/A570M Hot-Rolled Carbon Steel Sheet and Strip, Structural

Quality

ASTM B88 Seamless Copper Water Tube

ASTM C76 Reinforced Concrete Culvert, Storm Drain, and

Sewer Pipe

ASTM C296 Asbestos-Cement Pressure Pipe

ASTM C443-REV A Standard Specification for Joints for Circular

Concrete Sewer and Culvert Pipe, Using Rubber

Gaskets

ASTM C564 Rubber Gaskets for Cast Iron Soil Pipe and Fittings

ASTM D1248 Polyethylene Plastics Molding and Extrusion

Materials

ASTM D1784 Rigid Poly (Vinyl Chloride) (PVC) Compounds and

Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds

ASTM D1785 Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules

40, 80, and 120

ASTM D2241 Poly (Vinyl Chloride) (PVC) Plastic Pipe (SDR-PR)

ASTM D2513 Thermoplastic Gas Pressure Pipe, Tubing, and

Fittings

ASTM D2665 Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste,

and Vent Pipe and Fittings




150500 - 3

Reference Title

ASTM D2996 Filament-Wound Reinforced Thermosetting Resin

Pipe

ASTM D3034 Standard Specification for Type PSM Poly (Vinyl

Chloride) (PVC) Sewer Pipe and Fittings

ASTM D3261 Butt Fusion Polyethylene (PE) Plastic Fittings for

Polyethylene (PE) Plastic Pipe and Tubing

ASTM D4174 Cleaning, Flushing, and Purification of Petroleum

Fluid Hydraulic Systems

ASTM D4101 Propylene Plastic Injection and Extrusion Materials

ASTM F441 Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic

Pipe, Schedules 40 and 80

ASTM F876-20 Crosslinked Polyethylene (PEX) Tubing

AWWA C105 Polyethylene Encasement for Ductile-Iron Piping

for Water and Other Liquids

AWWA C110 Ductile-Iron and Gray-Iron Fittings, 3 Inch Through

48 Inch, for Water and Other Liquids

AWWA C111 Rubber-Gasket Joints for Ductile-Iron and Gray-Iron

Pressure Pipe and Fittings

AWWA C115 Flanged Ductile-Iron and Gray-Iron Pipe with

Threaded Flanges

AWWA C151 Ductile-Iron Pipe, Centrifugally Cast in Metal Molds

or Sand-Lined Molds, for Water or Other Liquids

AWWA C200 Steel Water Pipe 6 Inches and Larger

AWWA C205 Cement-Mortar Protective Lining and Coating for

Steel Water Pipe--4 In. and Larger--Shop Applied

AWWA C206 Field Welding of Steel Water Pipe

AWWA C207 Steel Pipe Flanges for Waterworks Services--Sizes

4 In. through 144 In.

AWWA C208 Dimensions for Fabricated Steel Water Pipe

Fittings

AWWA C209 Cold-Applied Tape Coating for Special Sections,

Connections, and Fittings for Steel Water Pipelines

AWWA C210 Liquid Epoxy Coating Systems for the Interior and

Exterior of Steel Water Pipe

AWWA C214 Tape Coating Systems for the Exterior of Steel

Water Pipelines

AWWA C301 Prestressed Concrete Pressure Pipe, Steel Cylinder

Type, for Water and Other Liquids

AWWA C303 Reinforced Concrete Pressure Pipe--Steel Cylinder

Type, Pretensioned, for Water and Other Liquids

AWWA C600 Installation of Ductile-Iron Water Mains and Their

Appurtenances

AWWA C651 Disinfecting Water Mains

AWWA C900 Polyvinyl Chloride (PVC) Pressure Pipe, 4 Inches

Through 12 Inches, for Water

AWWA M11 Steel Pipe--A Guide for Design and Installation

CISPI 301 Specification Data for Hubless Cast Iron Sanitary

System with No-Hub Pipe and Fittings

FEDSPEC L-C-530B(1) Coating, Pipe, Thermoplastic Resin or

Thermosetting Epoxy

MIL-H-13528B Hydrochloric Acid, Inhibited, Rust Removing




150500 - 4

Reference Title

MIL-STD-810C Environmental Test Methods

SAE J1227 Assessing Cleanliness of Hydraulic Fluid Power

Components and Systems

UPC Uniform Plumbing Code

B. Fittings and Coupling Compatibility:

1. To assure uniformity and compatibility of piping components, fittings and couplings

for grooved end piping systems shall be furnished by the same manufacturers.

1.03 SUBMITTALS



2. A copy of this specification section with each paragraph check-marked to indicate

specification compliance or marked to indicate requested deviations from

specification requirements. Check-marks (✓) denote full compliance with a

paragraph as a whole. Underline deviations and denote each deviation with a

number in the margin to the right of the identified paragraph. The remaining portions

of the paragraph not underlined will signify compliance on the part of the Contractor

with the specifications. Include a detailed, written justification for each deviation.

Failure to include a copy of the marked-up specification section along with




3. Piping layout drawings, showing locations of all proposed hangers, supports and

restraints per Paragraph 2.04 of this Section, and in compliance with Section 01330.

PART 2 PRODUCTS

2.01 PIPING MATERIALS

A. Unless otherwise specified, piping materials, including pipe, gaskets, fittings, connection

and joint assemblies, linings and coatings, shall be selected from those listed on the

piping system specification sheets. Piping materials shall conform to detailed

specifications for each type of pipe and piping appurtenance specified in other sections

of Division 15.

2.02 PIPING IDENTIFICATION

A. Plastic Coding Markers:

1. Plastic markers for coding pipe shall conform to ANSI A13.1 and shall be as

manufactured by W. H. Brady Company, Seton Name Plate Corporation, Marking

Services Inc., or equal. Markers shall be the mechanically attached type that are

easily removable; they shall not be the adhesive applied type. Markers shall consist

of pressure sensitive legends applied to plastic backing which is strapped or

otherwise mechanically attached to the pipe. Legend and backing shall be resistant

to petroleum based oils and grease and shall meet criteria for humidity, solar

radiation, rain, salt, fog and leakage fungus, as specified by MIL-STD-810C. Markers




150500 - 5

shall withstand a continuous operating temperature range of -40 degrees F to 180

degrees F. Plastic coding markers shall not be the individual letter type but shall be

manufactured and applied in one continuous length of plastic.

2. Markers bearing the legends on the background colors specified in the PIPESPEC

shall be provided in the following letter heights:

Outside Pipe Diameter,1

Inches

Letter Height,

Inches

Less than 1-1/2 1/2

1-1/2 through 3 1-1/8

Greater than 3 2-1/4

1 Outside pipe diameter shall include insulation and jacketing.

3. In addition, pipe markers shall include uni- and bi-directional arrows in the same

sizes as the legend. Legends and arrows shall be white on blue or red backgrounds

and black on other specified backgrounds.

B. Plastic Tracer Tape:

1. Tracer tape shall be 6 inches wide, colored the same as the background colors as

specified in Table A, paragraph 3.06, and made of inert plastic material suitable for

direct burial. Tape shall be capable of stretching to twice its original length and shall

be as manufactured by Allen Systems, W. H. Brady Co., Seton Name Plate

Corporation, Marking Services Inc., or equal.

2. Two messages shall be printed on the tape. The first message shall read "CAUTION

CAUTION CAUTION PIPE BURIED BELOW" with bold letters approximately 2 inches

high. The blank shall be filled with the particular system fluid such as chlorine,

oxygen or sulfur dioxide. The second message shall read "CALL____" with letters

approximately 3/4 inch high. Both messages shall be printed at maximum intervals

of 2 feet.

2.03 VALVES

A. Valves of the same size and service shall be provided by a single valve manufacturer.

Packing shall be nonasbestos material. Actual length of valves shall be within 1/16 inch

(plus or minus) of the manufacturer's specified length. Flanges shall meet the

requirement of ANSI B16.5. Push-on and mechanical joints shall meet the requirements

of AWWA C111. Valve operators are specified in Sections 15184 and 15185.

2.04 PRODUCT DATA

A. Product data on piping materials shall be provided in accordance with Section 01330

where specified.

B. Product data on valves specified in the individual piping specification sheets

(PIPESPECS) shall be provided in accordance with Section 01330.

C. Piping layout drawings shall be transmitted to the Owner a minimum of 2 weeks prior to

construction. Drawings shall be original layouts by the Contractor; photocopies of

contract drawings are not acceptable.




150500 - 6

PART 3 EXECUTION

3.01 INSTALLATION

A. Location:

1. Piping shall be provided as specified except for adjustments to avoid architectural

and structural features and shall be coordinated with electrical construction.

B. Piping Sizes:

1. Where the size of piping is not specified, the Contractor shall provide piping of the

sizes required by UPC. Unless specified otherwise, small piping (less than 1 inch in

diameter) required for services not described by UPC shall be 1/2 inch.

C. Pipe Support, Anchorage and Seismic Bracing:

1. Refer to Section 15096 and Section 15097.

2. General: Piping shall be supported by anchor brackets, guides, saddles or hangers.

Acceptable types of supports, guides, saddles, hangers and structure attachments

for general pipe support, expansion/ contraction and for seismic bracing, as well as

anchorage details, are shown on the drawings. Minimum spacing shall be as

specified for supports and for seismic bracing. Where a specific type of support or

anchorage is indicated on the drawings, then only that type shall be used there.

Piping shall be vertically supported by anchor brackets, guides, saddles or hangers

and shall be seismically braced where indicated to resist lateral load. Supports shall

be provided on each run at each change of direction. Pipe supports shall be hot-dip

or mechanically galvanized. Unless otherwise specified, existing pipes and supports

shall not be used to support new piping.

3. Piping Connections to Machines: Piping at machine connections shall be aligned in

all planes to permit insertion of bolts at bolted connections or coupling screwed

connections without using jacks, come-a-longs or other mechanical means to align

field piping with the connections at the machines. Bolts shall not be forced into

mating flange bolt holes and shall be capable being withdrawn using finger pressure

alone. The use of ‘dutchmen’ mitered sections or similar specials to achieve the

required alignment with machine connections is strictly prohibited.

D. Anchorage for Buried Piping:

1. All plugs, caps, tees and bends in buried pressure piping systems shall be anchored

by means of reaction backing or restrained joints as specified.

E. Bedding and Backfill:

1. Bedding and backfill for buried piping shall be as specified.

F. Flexibility

1. Unless otherwise specified, piping passing from concrete to earth shall be provided

with two pipe couplings or flexible joints as specified in Section 15085.




150500 - 7

3.02 PIPING IDENTIFICATION

A. Pipe Coding:

1. After application of the specified coating and insulation systems, exposed piping,

interior and exterior, and piping in ceiling spaces, pipe trenches, pipe chases and

valve boxes shall be identified with plastic markers as specified in paragraph 2.02

Plastic Coding Markers. Legend markers and directional arrows shall be located at

each side of walls, floors and ceilings, at one side of each piece of equipment, at

piping intersections, and at approximately 50-foot centers.

B. Plastic Tracer Tape:

1. A single line of tape as specified in paragraph 2.02 Plastic Tracer Tape shall be

provided 2.5 feet above the centerline of buried [insert required systems] pipe. For

[insert required systems] pipelines buried 8 feet or greater below finished grade,

contractor shall provide a second line of tape 12 inches below finished grade, above

and parallel to each buried pipe. Tape shall be spread flat with message side up

before backfilling.

3.03 VALVE IDENTIFICATION

A. Stainless steel tags bearing the specified valve number stamped in 1/4-inch high letters

shall be installed on valve flanges in a position visible from floor level. Flangeless valves

8 inches in diameter and larger shall have tags attached to the valve body by self-tapping

corrosion resistant metal screws. Flangeless valves 6 inches in diameter and smaller

shall have tags attached to the valve stem by stainless steel wire. Wire shall be 0.063

inch minimum.

3.04 TESTING

A. General:

1. Upon completion of piping, but prior to application of insulation on exposed piping,

the Contractor shall test the piping systems. Pressures, media and test durations

shall be as specified in the PIPESPEC. Equipment which may be damaged by the

specified test conditions shall be isolated. Testing shall be performed using

calibrated test gages and calibrated volumetric measuring equipment to determine

leakage rates. Each test gage shall be selected so that the specified test pressure

falls within the upper half of the gage's range. Unless otherwise specified, the

Contractor shall notify the Construction Manager 24 hours prior to each test.

2. Unless otherwise specified, testing, as specified herein, shall include existing piping

systems which connect with new pipe systems. Existing pipe shall be tested to the

nearest existing valve. Any piping which fails the test shall be repaired. Repair of

existing piping will be considered and paid for as extra work.

3. Where testing existing chlorine and sulfur dioxide systems to the nearest isolation

valve, Contractor shall provide a tee in the line adjacent to the valve. The branch

outlet on the tee shall be valved and used for cleaning, pressure testing, draining,

and drying the line. Unless otherwise indicated, the existing chlorine or sulfur dioxide

system shall not be shut down during testing or connecting the tee and valve. Prior to

placing the line in service, the valve on the branch outlet shall be plugged or sealed

with a blind flange or threaded plug. Contractor shall be responsible for all damage to

the existing system as a result of this work.




150500 - 8

B. Gas, Air, and Vapor Systems:

1. The Contractor shall test steam lines hydrostatically in accordance with the ASME

procedure for testing pressure piping.

2. Testing medium and procedures for chlorine and sulfur dioxide systems are specified

in paragraph 3.04 Chlorine and Sulfur Dioxide Systems.

3. Unless otherwise specified, the testing medium for other gas, air and vapor systems

shall be as follows:

Pipeline Size Specified Test Pressure Testing Medium

2 inch and smaller 75 psi or less Air or water

2 inch and smaller Greater than 75 psi Water

Greater than 2 inch 3 psi or less Air or water

Greater than 2 inch Greater than 3 psi Water

4. The allowable leakage rate for hazardous gas systems, insulated systems, and

systems tested with water shall be zero at the specified test pressure throughout the

specified test period. Hazardous gas systems shall include sulfur dioxide, chlorine,

propane, sludge gas and natural gas systems.

5. The allowable leakage rate for other systems tested with air shall be based on a

maximum pressure drop of 5 percent of the specified test pressure for the duration

of the period. Prior to starting a test interval using air, the air shall be at ambient

temperature and specified test pressure.

C. Liquid Systems:

1. Leakage shall be zero at the specified test pressure throughout the specified

duration for the following systems: exposed piping, buried insulated piping, and

buried or exposed piping carrying liquid chemicals. Testing procedures for chlorine

and sulfur dioxide systems are specified in paragraph 3.04 Chlorine and Sulfur

Dioxide Systems. Testing procedures for hydraulic and lube oil systems are specified

in paragraph 3.04 Hydraulic and Lube Oil Systems. Unless otherwise specified,

leakage from other buried liquid piping systems shall be less than 0.02 gallon per

hour per inch diameter per 100 feet of buried piping.

D. Drains:

1. Drain systems, other than pumped drain systems, shall be tested in accordance with

UPC.

3.05 CLEANING AND FLUSHING

A. General:

1. Piping systems shall be cleaned following completion of testing and prior to

connection to operating, control, regulating or instrumentation equipment. The

Contractor may, at his option, clean and test sections of buried or exposed piping

systems. Use of this procedure, however, will not waive the requirement for a full

pressure test of the completed system. Unless specified otherwise, piping 24 inches

in diameter and smaller shall first be cleaned by pulling a tightly fitting cleaning ball

or swab through the system.




150500 - 9

B. Temporary Screens:

1. Upon completion of the cleaning, the Contractor shall connect the piping systems to

related process equipment. Temporary screens, provided with locator tabs which

remain visible from the outside when the screens are in place, shall be inserted in

pipelines at the suction of pumps and compressors in accordance with the following

table:

Equipment Suction or Piping Size, Inches Maximum Screen Opening, Inches

0 –1 1/16

1-1/4 – 3 1/4

3-1/2 – 6 1/2

Over 6 1

2. The Contractor shall maintain the screens during testing, initial start-up, and initial

operating phases of the commissioning process. In special cases, screens may be

removed as required for performance tests. The Contractor shall remove the

temporary screens and make the final piping connections after the screens have

remained clean for at least 24 consecutive hours of operation. Systems handling

solids are exempted.

C. Gas and Air Systems:

1. Unless otherwise specified, gas and air system piping 6 inches in diameter and

smaller shall be blown out, using air or the testing medium specified. Piping larger

than 6 inches shall be cleaned by having a swab or "pig" drawn through the separate

reaches of pipe. After connection to the equipment, it shall then be blown out using

the equipment. Upon completion of cleaning, the piping shall be drained and dried

with an airstream. Sludge gas, natural gas and propane systems shall be purged with

nitrogen and a nitrogen pad maintained at 10 psi until put in service. Chlorine and

sulfur dioxide systems shall be cleaned in accordance with paragraph 3.05 Chlorine

and Sulfur Dioxide Systems.

D. Liquid Systems:

1. After completion of cleaning, liquid systems, unless otherwise specified, shall be

flushed with clean water. With temporary screens in place, the liquid shall be

circulated through the piping system using connected equipment for a minimum

period of 15 minutes and until no debris is collected on the screens. Liquid chlorine

and sulfur dioxide lines shall be cleaned in accordance with paragraph 3.05 Chlorine

and Sulfur Dioxide Systems.

E. Potable Water Systems:

1. Potable water piping systems shall be flushed and disinfected in accordance with

AWWA C651.




150500 - 10

3.06 PIPING SPECIFICATION SHEETS (PIPESPEC)

A. Piping and valves for groupings of similar plant processes or types of service lines are

specified on individual piping specification sheets (PIPESPECS). Piping services are

grouped according to the chemical and physical properties of the fluid conveyed and/or

by the temperature or pressure requirements. Each grouping of services (PIPESPEC) is

identified by a piping system number. Piping services specified in the PIPESPECS and on

the drawings are alphabetically arranged by designated service symbols as shown in

Table A. Table A also indicates the system number, fluid category, and pipe marker

background color of each service.

Table A. Piping Services

Symbol Service System Fluid Category Pipe color / pipe

marker color

NPW/H

NPW

Non-Potable Water/Hot

Non-Potable Water

7 Water Gray / Black

HPHW High-Pressure Hot Water 11 Water Red / Black

FOG

FOG Rec

FF

Fats, Oils and Grease

Fats, Oils and Grease Recirculation

Fats, Oils and Grease Feed

14 Fats, Oils and Grease Brown / Yellow

FA Foul Air 22 Vapor NONE / Red

SAN

SD

Sanitary Sewer

Storm Drain

24 Wastewater NONE / NONE




150500 - 11

3.06 PIPING SPECIFICATION SHEETS—PIPESPEC

Piping Symbol/Service NPW/H—Non-Potable Water / Hot System—7

NPW – Non-Potable Water

Test Requirements:

Medium: Water; ref. spec paragraph 3.04 Liquid Systems.

Pressure: 150 psig

Duration: 60 minutes

Gasket Requirements:

Flange: Compressed gasketing consisting of organic fibers (Kevlar) and

neoprene binder

Exposed Pipe and Valves:

(See drawings for pipe size and valve type. See Remarks for insulation requirements.)

(3" and smaller)

Pipe: Copper tube; ASTM B88, Type L, drawn. Ref. spec Section

15066.

Conn; solder type with threaded or flanged adapters for valves.

Ftgs; wrought copper or bronze, ANSI B16.22.

(2 1/2" and smaller)

Valves: Ball; Jamesbury Fig. 351, Nibco T-580, or equal.

Globe; Crane 7TF or 17TF, Lunkenheimer 123 or 214, or equal.

Swing check; Crane 137, Lunkenheimer 230, or equal.

Buried and Encased Pipe and Valves for Hose Racks:

(See drawings for pipe size and valve type. Omit coating on encased pipe.)

(3" and smaller)

Pipe: Copper tube; ASTM B88, Type K, annealed or drawn.

Conn; solder type, with threaded or flanged adapters for valves.

Ftgs; wrought copper or bronze, ANSI B16.22.

Valves: N/A

Buried and Encased Pipe and Valves for Seal Water and Screen Wash Water under screen slab:

(See drawings for pipe size and valve type. Omit coating on encased pipe.)

(3" and smaller)

Pipe: Crosslinked polyethylene (PEX); ASTM F876-20, PEX-A.

Conn; clamp type, with stainless steel cinch clamps.

Ftgs; poly crimp, ASTM F2159.

Valves: N/A




150500 - 12

Remarks:

1. Manual air vents shall be provided at the high points and drains provided at the low

points of each reach of pipeline as specified in Section 15095-2.06.

2. Insulate exposed indoor and outdoor piping per Section 15250.

3. PEX piping for pump seal water (NPW) and screen wash water (NPW/H) shall be routed

through 4” Sch 40 PVC casing pipe embedded in screen slab.




150500 - 13


Piping Symbol/Service: HPHW – High-Pressure Hot Water System--11

Test Requirements:


Pressure: 3000 psig




neoprene binder


(See drawings for pipe size and valve type)

(2" and smaller)

Pipe: Steel; ASTM A53, Grade B, Type S, Schedule 80, galvanized, no

lining. Dimensions per ASME B16.10.

Conn; threaded.

Ftgs; galvanized steel, ASTM A105, ANSI B16.11, Class 3000.

Valves: Ball; DynaQuip VLE Series, Apollo 72-100 Series, or equal.

Remarks:

1. Insulate exposed piping per Section 15250.




150500 - 14


Piping Symbol/Service: FOG /FOG REC– Fats, Oils and Greases System--14

FF – FOG Feed

Test Requirements:


Pressure: 100 psig



Flange: FKM or Viton


(See drawings for pipe size and valve type. See Remarks for insulation requirements)

(2" and smaller)

Pipe: CPVC; ASTM D1784, Class 23447-B, Sch. 80. Ref. spec

Section 15064.

Conn; plain end; solvent weld with threaded or flanged adapters

for valves.

Ftgs; CPVC, Sch. 80, socket weld.

Valves: Ball; threaded, ASTM D1784 Grade A, CPVC body, stem and

ball, PTFE seats, FKM or Viton O-rings. IPEX VXE/VKD or equal.

Non-clog Ball Check; per spec Section 15120.

(2 1/2" thru 6")

Pipe: Ductile Iron; AWWA Class 151, glass lining. Ref. spec Section

15062.

Conn; flanged.

Ftgs; malleable iron, ductile iron, or steel per spec Section

15062; ends to match pipe.

Valves: Eccentric plug; per spec Section 15110. Install valve with seat

upstream.

Non-clog Ball Check; per spec Section 15120.

Knife Gate: per spec Section 15136.

Buried and Encased Pipe and Valves:

(See drawings for pipe size and valve type.)

(3" and smaller)

Pipe: CPVC; ASTM D1784, Class 23447-B , Sch. 80, pre-insulated.

Ref. spec Section 15065. Provide magnetic tracer tape.

Conn; threaded with flanged adapters for valves.

Ftgs; CPVC, Sch. 80, solvent weld.

Valves: Eccentric plug; same as exposed with extension stem and valve

box. Coating M-1 per spec Section 09900.




150500 - 15

Remarks:

1. Manual air vents shall be provided at the high points and drains provided at the low points of

each reach of pipeline as specified in Section 15095-2.06.

2. Insulate exposed indoor FOG Feed piping per Section 15250

3. Insulate exposed outdoor piping per Section 15250.

4. Buried FF piping shall be pre-insulated CPVC piping. Refer to Section 15065.




150500 - 16


Piping Symbol/Service: FA--Foul Air System--22

Test Requirements:

Medium: Air; ref. spec paragraph 3.04 Gas, Air, and Vapor Systems.

Pressure: 15 psig


Gasket Requirements, 16” and smaller:

Flange: FKM or Viton


(See drawings for pipe size and valve type)

(16" and smaller)

Pipe: PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 80.

Piping and fittings exposed to sunlight shall be painted. Ref.

spec Section 15064.

Conn; plain end, solvent weld, flanged for valves 3 inches and

larger.

Ftgs; PVC, Sch. 80, solvent weld.

Valves: Butterfly; flanged, lever-operated, ASTM D1784 PVC body and

disc, 304 SST shaft, FKM or Viton seals, seats and O-rings.

Asahi/America Type 57, Hayward Series BYV or equal.

Remarks:

1. Coating per Section 09900.




150500 - 17


Piping Symbol/Service: D--Drain System--24

SD--Sanitary Drain

STD--Storm Drain

Test Requirements:

Medium: In accordance with Section 712, Uniform Plumbing Code.

Pressure: In accordance with Section 712, Uniform Plumbing Code.

Duration: In accordance with Section 712, Uniform Plumbing Code.



neoprene binder

Push-on/Mech Cpl: Nitrile or neoprene


(See drawings for pipe size.)

(3" and smaller)

Pipe: Steel; ASTM A53, galvanized. Ref. spec Section 15061.

Conn; taper threaded, ANSI B1.20.1.

Ftgs; cast iron, threaded drainage fittings, ASTM A126, ANSI

B16.12, galvanized.

Valves: None

(4" thru 12")

Pipe: Cast iron soil pipe (CISP); ASTM A74.

Conn; service hub and spigot compression type or hubless cast

iron sanitary system per CISPI 301.

Ftgs; CISP, ASTM A74, joint options to match pipe.

Valves: None

Buried and Encased Pipe and Valves Under and 5 Feet Outside Building


(12" and smaller)

Pipe: Cast iron soil pipe (CISP); same as exposed.

Valves: None

Buried and Encased Pipe and Valves Beyond 5 Feet Outside Building


(8" and smaller)




150500 - 18

Pipe: PVC; ASTM D1784, Class 12454-B, ASTM D2665, Sch. 40. Ref.

spec Section 15064. Provide magnetic tracer tape.

Conn; plain end, solvent weld.

Ftgs; PVC, socket type, DWV, ASTM D2665.

Valves: None

(10" and 12")

Pipe: PVC; ASTM D3034, SDR 35. Provide magnetic tracer tape.

Conn; Push-on with nitrile gasket.

Ftgs; PVC or IPS cast iron; ends to match pipe.

Valves: None

Remarks:

None

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Piping Systems Identification



15060 - 1

SECTION 15060

PIPING SYSTEM IDENTIFICATION

PART 1 GENERAL

1.01 SUMMARY

A. This section specifies the supply and installation of permanent identification labels and

markers for piping systems.


A. This section contains specific references to the following related sections. Additional

related sections may apply that are not specifically listed below.

1. Section 01330 – Submittal Procedures

2. Section 15050 – Piping Systems

1.03 REFERENCES

A. References:

1. This section contains references to the documents listed below. They are a part of

this section as specified and modified. Where a referenced document cites other

standards, such standards are included as references under this section as if

referenced directly. In the event of conflict between the requirements of this section

and those of the listed documents, the requirements of this section shall prevail.










later date, has been discontinued or has been replaced.

Reference Title

ASME A13.1 Scheme for the Identification of Piping Systems

ANSI Z535.1 Safety Colors/APWA Uniform Color Code for Marking Underground Utilities

1.04 DEFINITIONS

A. Terminology used in this Section conforms to the following definitions:

1. Embedded/Encased piping: Piping enveloped in concrete, typically under structures

or under roadways.

2. Exposed: All area exposures other than buried, submerged, or encased/embedded.

3. Buried: Below grade walls or roofs; locations covered and in contact with earth/soil.




15060 - 2

1.05 SUBMITTALS



2. Provide a full line product brochure showing available Piping System Marker and

Detectable Warning Tape standard text and color options. Submit all text and colors

proposed for use.

3. Provide manufacturer’s recommended installation instructions for Detectable

Warning Tape.

4. Provide product brochures and data sheets for tracer wire and splice kits. Submit all

wire insulation colors proposed for use.

5. Submit proposed tracer wire access box(es) for test leads. Submit electrical

continuity test results upon completion.

6. A copy of this Section, addendum updates included, with each paragraph check-

marked to indicate compliance or marked to indicate requested deviations from

Section requirements.


1. Procedures: Section 01330

2. Electrical continuity test results.

3. Sample of each piping identification plastic marker used.

4. Sample of each detectable warning tape used.

PART 2 PRODUCTS

2.01 PIPING SYSTEM MARKERS FOR EXPOSED PIPE

A. Identify material contained in exposed piping systems using a colored plastic marker

legend system conforming to ASME A13.1.

B. For exposed piping, provide pre-coiled mechanically attached type colored markers that

are easily removable. Adhesive type markers are not acceptable.

1. Resistant to petroleum based oils and grease and meet criteria for humidity, solar

radiation, rain, salt, fog, leakage and fungus specified by MIL-STD-810.

2. Withstand a continuous operating temperature range of -40 to 250 degrees.

3. Manufactured and applied in one continuous length of plastic including directional

arrows. Markers comprised of letters and directional arrows individually applied to

the maker are not acceptable. Legends and arrows printed on polyester subsurface

and over laminated with Tedlar.

4. Text size per ASME A13.1.

5. Marking Services Style MS-995, Brady Style B-689, or approved equal.

C. Each piping system marker to be color coded for identification and labelled with the

Process Service Identifier and directional flow arrows indicating the direction of flow in

the pipe. Piping System marker background colors are specified on drawing G004 for

each process service. Except for piping system markers with an orange, yellow or white

background color, provide white text and directional arrows for all piping system markers.

Provide black text and directional arrows for pipe markers with an orange, yellow or white

background.




15060 - 3

2.02 DETECTABLE WARNING TAPE AND TRACER WIRE FOR BURIED PIPE

A. Provide Detectable Warning Tape for all buried piping:

1. Detectable Warning Tape shall be 6 inches wide, colored per ANSI Z535.1 (APWA

Uniform Color Code for Marking Underground Utilities) and made of inert plastic material

suitable for direct burial with solid aluminum foil core. Minimum 5 mil laminate

thickness. Tin or nickel plated clips for joining sections of tape, as provided by the tape

manufacturer.

2. Allen Systems, W. H. Brady Co., Seton Name Plate Corporation, Marking Services Inc., or

approved equal.

3. Print two messages on buried Detectable Warning Tape. The first message reads

"CAUTION CAUTION CAUTION ________ PIPE BURIED BELOW" with bold letters

approximately 2 inches high. Fill the blank with the Process Service name. The second

message reads "CALL____" with letters approximately 3/4 inch high. Both messages

printed at maximum intervals of 2 feet. Fill the blank with phone number provided by the

Construction Manager.

PART 3 EXECUTION

3.01 INSTALLATION OF PIPING SYSTEM MARKERS

A. Provide piping system markers and direction arrows at locations conforming to ASME

A13.1 and at the following locations:

1. Apply intermittent markings on straight pipe runs, close to all valves, fittings, and

adjacent to all changes in direction.

2. Where pipes pass through walls, partitions, and floors, apply markings on both sides

of walls, partitions, and floors.

3. At point of entry and leaving each pipe chase and/or confined space, and piping

accessible at each access opening.

4. Adjacent to valves and where valves are in series at intervals of no more than 6 feet.

5. At least once in each room and at maximum spacing of 40 feet. Exception: gas piping

to be identified at 6-ft intervals in ceiling plenums.

6. Spacing for markings not less than 1 foot.

7. At the beginning and end points of each run; and, at each piece of equipment in each

run.

B. Visibility

1. Place identification on the bottom of the piping system for pipe systems located near

ceiling or above the normal line of sight.

2. Place identification on the side of the piping systems for pipe systems located at the

normal line of sight or below.

3. Place identification at approximate line of sight for vertical pipe systems.

3.02 INSTALLATION OF DETECTABLE WARNING TAPE

A. Install a continuous ribbon of Detectable Warning Tape as specified for ALL buried piping.

B. Multiple pipes less than 4 inches in diameter installed in a common trench may be

provided with a single ribbon of tape per trench. If the total width of such utilities within

the common trench exceeds 3 feet, provide two parallel ribbons of tape spaced equally.




15060 - 4

C. Provide a separate detectable warning tape for each pipe that is 4 inches or greater in

size.

D. Install the tape in accordance with manufacturer recommendations.

E. At end-to-end and branch connections, provide electrical continuity connectors for

detectable tape to mechanically and electrically connect ends together as recommended

by the manufacturer.

F. Provide a single line of tape 2.5 feet above the centerline of buried pipe. For pipelines

buried 8 feet or greater below finished grade, provide a second line of tape 12 inches

below finished grade, above and parallel to each buried pipe. Spread tape flat with

message side up before backfilling.

3.03 INSTALLATION OF TRACER WIRE

A. Tracer wire shall be a continuous, fully functioning, and tested system to include all

appurtenances including splices and wire access boxes at grade.

B. Tracer wire laid along the top of the pipe prior to backfilling. Secure in place with tape

every 20 feet. Where the pipe is encased or provided with concrete collars or cut-off

walls, lay the wire on top of the encasement (do not encase the wire). Do not pull the

wire taut; leave sufficient slack to allow for pipe movement and future repairs.

C. Splice tracer wire using the specified silicone-filled splice kits in accordance with

manufacturer recommendations. Ensure the silicone fully encapsulates un-insulated

wire ends and are made watertight.

D. Pull tracer wire up into all valve boxes, cleanout access boxes, and into all utility cabinets

and meter boxes installed on the pipeline. For each wire end, provide an 18-inch long

length of extra wire (coiled and tucked out of the way in an accessible location) for

connection to utility locating equipment.

E. Where the pipeline enters structures, vaults, tanks, or buildings, provide a wire access

box at grade adjacent to the structure or building for termination of the tracer wire.

Provide an 18-inch long length of extra wire (coiled and tucked into the box) for

connection to utility locating equipment. Also provide boxes at each pipeline branch,

cross or tee, and at intermediate spacing along the pipeline not to exceed 1,000 feet

(except where pipeline valves with valve boxes provide the required wire access at those

locations and intervals).

F. Upon completion and backfill of the pipeline, test and demonstrate electrical continuity

of each segment of tracer wire. Submit test results to the Owner indicating the location

of the tested segment. Use conductive testing method; inductive test methods are not

acceptable. Repair all faulty work at no additional cost to the Owner until the system is

functional and approved.




15060 - 5


A. Comply with manufacturer’s handling and installation instructions.

B. Provide continuity testing of tracer wire as specified herein.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Steel Pipe



15061- 1

SECTION 15061

STEEL PIPE

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies steel pipe and fittings.


A. REFERENCES:

















Reference Title

ANSI B16.3 Malleable Iron Threaded Fittings, Class 150 and 300

ANSI B16.9 Factory-Made Wrought Steel Buttwelding Fittings

ANSI B16.11 Forged Steel Fittings, Socket-Welding and Threaded

ASTM A36/A36M Structural Steel

ASTM A47 Ferritic Malleable Iron Castings

ASTM A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless

ASTM A105/A105M Forgings, Carbon Steel, for Piping Components

ASTM A106 REV A Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A197 Cupola Malleable Iron

ASTM A234/A234M Pipe Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and

Elevated Temperatures

ASTM A283/A283M REV A Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes and

Bars


ASTM A570/A570M Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality

ASTM A572/A572M REV B High Strength Low Alloy Columbium-Vanadium Steels of Structural Quality

AWWA C200 Steel Water Pipe 6 Inches and Larger




15061- 2

Reference Title

AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe--4 In.

and Larger-- Shop Applied


AWWA C207 Steel Pipe Flanges for Waterworks Services--Sizes 4 In. Through 144 In.

AWWA C208 Dimensions for Fabricated Steel Water Pipe Fittings

AWWA C209 Cold-Applied Tape Coating for Special Sections, Connections, and Fittings

for Steel Water Pipelines

AWWA C210 Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water

Pipe

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

AWWA C600 Installation of Ductile-Iron Water Mains and Their Appurtenances

AWWA M11 Steel Pipe--A Guide for Design and Installation

SSPC-SP10 Near-White Blast Cleaning

B. TESTING:

1. Factory testing shall conform to the requirements of ASTM A53, ASTM A106, or

AWWA C200 as applicable.

PART 2 PRODUCTS

2.01 PIPE MATERIALS

A. Steel pipe and fittings shall be provided in accordance with ASTM A53, ASTM A106, or

AWWA C200 as specified in Section 15050, Piping Systems.

B. Steel for pipe fabricated to meet requirements of AWWA C200 shall conform to the

requirements of ASTM A36, ASTM A572, Grade 42, ASTM A570, Grades 33 and 36, or

ASTM A283, Grade D. Steel for ASTM A53 and ASTM A106 pipe shall be Grade B.

2.02 PIPE MANUFACTURE

A. Unless otherwise specified, ASTM A53 pipe shall be Type E, electric resistance welded or

Type S, seamless pipe as specified in Section 15050. The minimum wall thickness for

ASTM A53 or ASTM A106 pipe shall be Schedule 40 for pipe 10 inch diameter and less

and 3/8 inch for pipe 12 inch through 24 inch diameter. Increased shell thickness shall

be provided where specified.

2.03 CONNECTIONS

A. Connections shall be as specified in Section 15050 and shall conform to Section 15085.

Coating for buried connections shall be as specified in paragraph 15085-2.06.




15061- 3

2.04 FITTINGS AND APPURTENANCES

A. Galvanized, cast iron threaded drainage fittings shall conform to the requirements of

ASTM A126, ANSI B16.12.

B. Unless otherwise specified, all fittings shall be rated for pressure and loadings equal to

the pipe.

2.05 PIPE COATING

A. EPOXY:

1. Unless otherwise specified, pipe and fittings shall be coated with a liquid epoxy as

specified in AWWA C210 with the following exceptions:

a. No coal tar products shall be incorporated in the liquid epoxy.

b. The curing agent may be an amidoamine as well as the other curing agents listed

in AWWA C210.

2. The coating shall be applied to a minimum thickness of 16 mils in not less than two

coats.

2.06 JOINT GASKETS

A. Joint gaskets shall be as specified in Section 15075.

2.07 PRODUCT DATA


1. Affidavits of Compliance with AWWA C200, ASTM A53, or ASTM A106 as applicable.

2. Contractor's layout drawings as specified in paragraph 15050-2.04.

PART 3 EXECUTION

3.01 INSTALLATION

A. GENERAL:

1. Pipe shall be installed in accordance with AWWA M11, Chapter 16. Welded joints

shall be in accordance with AWWA C206 and Section 15085.

2. Sleeve-type mechanical pipe couplings shall be provided in accordance with AWWA

M11 and paragraph 15085-2.02 A.

3. Pipe lining and coatings at field joints shall be applied as specified in paragraphs

15061-2.05 and 2.06.

4. Unless otherwise specified, buried mechanical couplings and valves shall be field

coated as specified in paragraph 15085-2.06.

B. ANCHORAGE:

1. Anchorage shall be provided as specified. Calculations and drawings for proposed

alternative anchorage shall be submitted in accordance with Section 01330.




15061- 4

3.02 TESTING

A. Hydrostatic testing shall be in accordance with Section 4 of AWWA C600 except that test

pressures and allowable leakage shall be as listed in Section 15050.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Ductile Iron Pipe



15062 - 1

SECTION 15062

DUCTILE IRON PIPE

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies ductile iron pipe, ductile fittings and gaskets.

B. Definition:

1. Where cast iron pipe is specified, the term and symbol shall mean ductile iron pipe.

1.02 REFERENCES















or replaced.

Reference Title

ANSI A21.14 Ductile-Iron Fittings 3 In. Through 24 In., for Gas

ANSI A21.52 Ductile-Iron Pipe, Centrifugally Cast, in Metal Molds or Sand Lined Molds for Gas

ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800


ASTM A716 Ductile-Iron Culvert Pipe

ASTM C150 Portland Cement

AWWA C104

(ANSI A21.4)

Cement-Mortar Lining for Ductile- Iron and Gray-Iron Pipe and Fittings for Water

AWWA C110

(ANSI A21.10)

Ductile-Iron and Gray-Iron Fittings, 3 In. Through 48 In., for Water and Other Liquids

AWWA C111

(ANSI A21.11)

Rubber-Gasket Joints for Ductile- Iron and Gray-Iron Pressure Pipe and Fittings

AWWA C115

(ANSI A21.15)

Flanged Ductile-Iron and Gray-Iron Pipe With Threaded Flanges

AWWA C150

(ANSI A21.50)

Thickness Design of Ductile-Iron Pipe

AWWA C151

(ANSI A21.51)

Ductile-Iron Pipe, Centrifugally Cast, in Metal Molds or Sand-Lined Molds, for Water or

Other Liquids




15062 - 2

Reference Title

AWWA C153

(ANSI A21.53)

Ductile-Iron Compact Fittings, 3 In. Through 12 In. for Water and Other Liquids

AWWA C600 Installation of Ductile-Iron Water Mains and Their Appurtenances

AWWA C606 Grooved and Shouldered Type Joints

1.03 SUBMITTALS














3. Piping layout drawings as specified in Section 15050.

4. Manufacturer’s product data, catalog cuts, typical installation details, and

dimensions. Indicate each Piping System Schedule where the product will be used.

PART 2 PRODUCTS

2.01 GENERAL

A. Pipe design, materials and manufacture shall comply with the following documents:

Item Document

Thickness design AWWA C150

Manufacturing requirements

Water or other liquid AWWA C151

Gas ANSI A21.52

Gravity service pipe ASTM A716

Joints

Rubber gasket AWWA C111

Threaded flange AWWA C115

Fittings

Water or other liquid AWWA C110/AWWA C153

Gas ANSI A21.14

Cement mortar lining AWWA C104




15062 - 3

2.02 PIPE

A. Unless otherwise specified, ductile iron pipe shall be Class 50 and have nominal laying

lengths of 18 or 20 feet. For grooved-end pipe, wall thickness shall be minimum Class 53

except where the specified pressure requires heavier pipe.

2.03 GASKETS

A. Unless otherwise specified, gasket stock shall be composed of a Viton fluoroelastomer.

The compound shall contain not less than 66 percent by volume polymer fluorine

content.

2.04 FITTINGS

A. Unless otherwise specified, fittings shall conform to AWWA C110. Ends shall be flanged,

restrained mechanical joint, restrained push-on, or grooved to suit the conditions

specified. The AWWA C153 compact ductile iron fittings in sizes 3 through 12 inches are

an acceptable substitute for standard fittings unless otherwise specified. Long-radius

elbows shall be provided. Grooved end fittings shall comply with Section 15050-

1.02 Fittings and Coupling Compatibility.

2.05 JOINTS

A. Restrained Joints:

1. General: Unless otherwise specified, restrained joints are required for all exposed

and buried piping. Unless otherwise specified, restrained joints shall be flanged or

grooved end for exposed service and restrained push-on for buried service.

2. Flange Assemblies: Unless otherwise specified, flanges shall be ductile iron and shall

be threaded-on flanges conforming to ANSI/AWWA A21.15/C115 or cast-on flanges

conforming to ANSI/AWWA A21.10/C110. Flanges shall be adequate for 250 psi

working pressure. Bolt circle and bolt holes shall match those of ANSI B16.1, Class

125 flanges and ANSI B16.5, Class 150 flanges. Where specified, flanges shall be

threaded-on or cast-on flanges conforming to ANSI B16.1, Class 250.

a. Unless otherwise specified, bolts and nuts for flange assemblies shall conform

with Section 15095-2.01 Bolts. Gaskets shall be as specified in Section 15095-

2.01 Gaskets.

B. Bolts and Nuts: Corrosion-resistant bolts and nuts for use with ductile iron joints shall be

high-strength, low-alloy steel as specified in ANSI/AWWA C111/A21.11.

2.06 PIPE COATING

A. Refer to Section 09900.




15062 - 4

2.07 PIPE LINING

A. Glass Lining:

1. Where specified, pipe and fittings shall be glass lined with a dual layer coating

system of vitreous material to a minimum thickness of 10 mils. Glass lining shall

provide continuous coverage as tested by a low voltage holiday detector with only

isolated voids permitted due to casting anomalies. Voids, other than isolated

pinholes, shall be cause for rejection.

2. Ductile or cast iron pipe shall be bored, machined, or grit blasted to remove any

voids, protrusions or surface irregularities to obtain a smooth continuous surface for

glass lining. Pipe shall be at least Class 53 on diameters of 6 inches or greater

except for pipe to be bored or machined which shall be of a suitable wall thickness to

assure boring or machining will not impair minimum wall thickness required for Class

53. Four-inch pipe shall be Class 56. Fittings shall be ground or grit blasted to

remove any voids, protrusions or surface irregularities.

3. Glass lining shall be Ferrock MEH-32, Vitco SG-14, or equal.

2.08 PRODUCT DATA


1. Shop drawings.

2. Alignment drawings.

3. Certifications specified in the following documents:

a. ANSI A21.14, paragraph 14-4.2

b. ANSI A21.52, paragraph 52-4.2

c. ASTM A716, paragraph 4.2

d. AWWA C110, paragraph 10-5.3

e. AWWA C111, paragraph 11-7.1

f. AWWA C115, paragraph 15-4.2

g. AWWA C151, paragraph 51-5.2

h. AWWA C153, paragraph 53-6.3

i. AWWA C606, paragraph 4.1.1.1

PART 3 EXECUTION

3.01 INSTALLATION

A. General:

1. Piping runs specified on the drawings shall be followed as closely as possible.

Proposed deviations shall be submitted in accordance with Section 01330.

2. Pipe shall be installed in accordance with AWWA C600.

3. Connections to existing structures and manholes shall be made so that the finished

work will conform as nearly as practicable to the requirements specified for the new

manholes, including necessary concrete work, cutting and shaping. Concrete mortar

shaping within any structure and manhole shall be as specified.




15062 - 5

B. Insulating Sections:

1. Where a metallic nonferrous pipe or appurtenance is connected to ferrous pipe or

appurtenance, an insulating section shall be provided as specified in Section 15085-

3.05.

C. Anchorage:

1. Anchorage shall be provided as specified. Calculations and drawings for proposed

alternative anchorage shall be submitted in accordance with Section 01330.

3.02 ACCEPTANCE TESTING

A. Hydrostatic pressure tests shall be conducted in accordance with Section 4 of AWWA

C600 except that test pressures and allowable leakage shall be as listed in Section

15050.

B. The Contractor shall conduct the tests in the presence of the Construction Manager.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Thermoplastic Process Pipe

Engineer Project Number: 154061 15064 - 1


SECTION 15064

THERMOPLASTIC PROCESS PIPE

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies polyvinylchloride andchlorinated polyvinylchloride pipe and

fittings.

B. Pipe Designations:

1. For use in the Piping System Specification Sheets (PIPESPEC) in Section 15050 and

in this section, the following plastic pipe designations are defined:

Designation Definition

PVC Polyvinylchloride

CPVC Chlorinated polyvinylchloride


A. References:

















Reference Title

ASTM D1248 Polyethylene Plastics Molding and Extrusion Materials

ASTM D1784 Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl

Chloride) (CPVC) Compounds

ASTM D1785 Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120

ASTM D2241 Poly (Vinyl Chloride) (PVC) Plastic Pipe (SDR-PR)

ASTM D2464 Threaded Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80

ASTM D2466 Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40

ASTM D2467 Socket-Type Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80




Reference Title

ASTM D2564 Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings

ASTM D2657 Heat-Joining Polyolefin Pipe and Fittings

ASTM D2665 Poly (Vinyl Chloride) (PVC) Plastic Drain, Waste, and Vent Pipe and Fittings

ASTM D3034 Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings

ASTM D4101 Propylene Plastic Injection and Extrusion Materials

ASTM F402 Safe Handling of Solvent Cements and Primers Used for Joining

Thermoplastic Pipe and Fittings

ASTM F437 Threaded Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings,

Schedule 80

ASTM F438 Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings,

Schedule 40

ASTM F439 Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings,

Schedule 80

ASTM F441 Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80

ASTM F477 Elastomeric Seals (Gaskets) for Joining Plastic Pipe

ASTM F493 Solvent Cements for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe

and Fittings

1.03 SUBMITTALS

















PART 2 PRODUCTS

2.01 PVC PIPE

A. Pressure Pipe:

1. PVC material for pipe and fittings shall conform to ASTM D1784, Class 12454-B. Pipe

and fittings shall either be in accordance with ASTM D1785 or shall conform to ASTM

D2241 for standard dimension ratios: 160 psi pipe--SDR 26; 200 psi pipe--SDR 21;

250 psi--SDR 17. Pressure rating for pipe shall be in excess of test pressure specified

in Section 15050. Neoprene gaskets with push-on joints shall conform to ASTM

F477.




2. Schedule 80 PVC socket type fittings shall conform to ASTM D2467. Schedule 40

PVC fittings shall conform to ASTM D2466. PVC solvent weld cement for socket

connections shall meet the requirements of ASTM D2564. Schedule 80 PVC

threaded fittings shall conform to ASTM D2464. Fittings for gasketed pipe shall be

ductile iron or steel push-on IPS-sized pressure fittings rated for use with the

specified class of PVC pipe. Unless otherwise specified, fittings shall be lined and

coated in accordance with Section 15050 as applicable.

B. Nonpressure Pipe:

1. Gravity Sewer Pipe: PVC material for sewer pipe and fittings shall conform to Class

12454-B, as defined in ASTM D1784. Pipe and fittings shall meet the requirements

of ASTM D3034 for SDR 35. Neoprene gaskets with push-on joints shall conform to

ASTM F477.

2. DRAIN, Waste and Vent Pipe: PVC material for drain waste and vent (DWV) pipe and

fittings shall conform to Class 12454-B, ASTM D1784. Pipe and fittings shall conform

to ASTM D2665. Unless otherwise specified, connections shall be solvent weld.

Connections to traps, closet flanges, and nonplastic pipe shall be with approved

adapter type fittings designed for intended use. Solvent weld cement for socket

connections shall meet requirements of ASTM D2564.

2.02 CPVC PIPE

A. CPVC material for pipe and fittings shall conform to ASTM D1784, Class 23447-B. Pipe

and fittings shall be in accordance with ASTM F441. FKM or Viton gaskets shall conform

to ASTM D1418.

B. Schedule 80 CPVC socket type fittings shall conform to ASTM F439. Schedule 40 CPVC

socket type fittings shall conform to ASTM F438. CPVC solvent weld cement for socket

connections shall meet the requirements of ASTM F493. Schedule 80 CPVC threaded

type fittings shall conform to ASTM F437.

2.03 PRODUCT DATA


1. Manufacturer's certificates of compliance with the specified standards and

Contractor's layout drawings.

PART 3 EXECUTION

3.01 INSTALLATION

A. PVC pipe 3 inches in diameter and smaller shall be joined by means of socket fittings

and solvent welding in conformance with ASTM F402. Solvent-cemented joints shall be

made in strict compliance with the manufacturer's/supplier's instructions and

recommended procedures. Unless otherwise specified, PVC pipe 4 inches in diameter

and greater shall be joined by means of gasketed push-on joints and steel or ductile iron

push-on or mechanical joint fittings. Fittings shall be lined and coated as specified in

Section 15085. Unless otherwise specified, PVC and CPVC piping exposed to sunlight

shall be painted with coating system L-2 as specified in Section 09900.




B. Connections to different types of pipe shall be by means of flanges, specified adapters or

transition fittings. Where sleeve type couplings are used, both shall be uniformly torqued

in accordance with pipe manufacturer's recommendation. Foreign material shall be

removed from the pipe interior prior to assembly.

C. Unless otherwise specified, PE pipe and fittings 4 inch diameter and smaller shall be

joined by means of thermal socket fusion and pipe 6 inch and larger by thermal butt

fusion. Butt-fusion joining of the pipes and fittings shall be performed with special joining

equipment in accordance with procedures recommended by pipe manufacturer. Tensile

strength at yield of butt-fusion joints shall not be less than pipe. Flanged adapters shall

be provided for connection to valves and where specified.

3.02 TESTING

A. Testing of plastic piping shall be as specified in Section 15050.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Insulated Underground Piping



15065 - 1

SECTION 15065

INSULATED UNDERGROUND PIPING

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies pre-insulated liquid piping for direct burial installation. This

section does not provide specifications for insulation for piping installed in galleries,

rooms, pipe chases, or exposed to view. Fluid temperatures are limited to the range

40 degrees F to 210 degrees F.

B. Type:

1. Insulation shall be of the factory applied urethane foam type with a polyvinyl chloride

(PVC) jacket.

C. Performance And Service Requirements:

1. Insulated piping furnished under this specification shall be suitable for direct burial

or installation in pipe trenches. Fluid temperature shall be as listed in Section 15050

and Section 15250. Ground temperatures will range from 35 degrees F to 70

degrees F, and the piping may be installed below the water table.

D. Design Requirements:

1. Minimum insulation thicknesses, exclusive of jacket, shall be as follows:

Pipe O.D., inches Insulation thickness, inches

2 or smaller 2

2. A minus 15 percent tolerance, on the insulation thicknesses listed above, shall be

permitted for manufacturers' standard insulation systems.

E. Piping Systems:

1. The following piping systems, as defined in Section 15050, shall be insulated in

accordance with this section:

a. System 14: FOG Feed (FF)

1.02 REFERENCES














15065 - 2





or replaced.

Reference Title

ANSI B31 Code for Pressure Piping

ASTM C591 Unfaced Preformed Rigid Cellular Polyurethane Thermal Insulation

ASTM D1784 Rigid Poly (vinylchloride); (PVC) Compounds and Chlorinated Poly (vinyl-

chloride) (CPVC) Compounds

ASTM D2341 Rigid urethane foam

1.03 SUBMITTALS

















5. A complete description of the preinsulated piping and accessories in sufficient detail

to demonstrate compliance with these specifications.

PART 2 PRODUCTS

2.01 ACCEPTABLE MANUFACTURERS

A. Preinsulated piping systems shall be Perma-Pipe/Ricwil, Thermal Pipe Systems Weldtite,

or equal, modified as necessary to provide the specified performance and features.

2.02 MATERIALS

A. Carrier Pipe:

1. Unless otherwise specified, carrier pipe materials shall be CPVC as specified in

Section 15050, Piping System Specification Sheets, for System 14.

B. Urethane Foam Insulation:

1. The urethane foam shall conform to ASTM C591, Type II.




15065 - 3

C. Insulation Jacket:

1. All PVC shall conform to ASTM D1784, Class 12454-B. The minimum jacket

thickness shall be 60 mils and shall be suitable for H-20 highway loading with 2 feet

of cover.

D. Shrinkable Sleeves:

1. Shrinkable sleeves for field joints shall be compatible with the PVC jacket. Shrinkable

sleeves shall be fabricated from radiation cross-linked semirigid polyethylene, coated

on all inside surfaces with thixotropic adhesive designed to flow and provide a

complete seal when heated.

2.03 MANUFACTURING

A. General:

1. Pipe sections shall be prefabricated in such a way that the urethane completely fills

the annular space between the carrier pipe and the PVC jacket. The exposed

insulation at the end of each section shall be sealed with a factory-applied, high

temperature, watertight sealant. The carrier pipe shall extend a minimum of 6 inches

beyond the insulation for field welding.

B. Anchors:

1. Anchor plates shall be factory fabricated and welded to the carrier pipe. The PVC

jacket shall extend up to the anchor plate and be factory sealed to the anchor plate.

C. Fittings:

1. Fittings shall be factory fabricated and pre-insulated with urethane foam insulation.

The insulation shall be protected with a PVC plastic jacket of the same thickness and

quality as that of the straight pipe. All miters on the PVC jacket at fittings shall be

welded by a thermal set welding process to provide a continuous jacket integrity.

D. Expansion Elbows And Loops:

1. Prefabricated elbows, expansion loops, and tees shall be provided, where specified.

All pre-insulated fittings that must provide compensation for pipe expansion and/or

contraction shall be installed in a suitably sized jacket and insulated with flexible

polyurethane foam insulation. The straight units adjoining expansion fittings shall

also be insulated with flexible polyurethane foam insulation to compensate for lateral

pipe movement.

E. End Seals:

1. End seals shall be provided on ends of each section of preinsulated pipe. The end

seals shall be watertight to protect the exposed insulation.




15065 - 4

2.04 PRODUCT DATA


1. Manufacturer's certification in accordance with paragraph 3.06.

2. Certification that the jacket meets the requirement of paragraph 2.02 Insulation

Jacket.

3. Manufacturer's recommended field installation instructions including pipe jointing

techniques, joint insulation, and jacket sealing.

PART 3 EXECUTION

3.01 GENERAL

A. The preinsulated piping system shall be installed in strict accordance with the

manufacturer's recommendations.

3.02 FIELD TESTING

A. Prior to insulating any field joints, individual pipe sections shall be hydrostatically tested

at the test pressure and temperature indicated in Section 15050. The Construction

Manager shall be notified in writing 48 hours prior to testing. Any leaks shall be repaired,

and the system shall be retested until no leaks are detected by the Construction

Manager. Field joints shall be insulated after hydrostatic testing has been completed.

3.03 FIELD JOINTS

A. Carrier pipe field joints shall be as specified in Section 15050. After jointing and pressure

testing, rigid urethane insulating material or foamed-in-place urethane of the same

density and thickness as the pipe section shall be applied to the joint area. The

insulation shall be sealed to the PVC jacket using heat shrinkable sleeves. All material

used to insulate and seal field joints shall be supplied by the piping system

manufacturer.

3.04 FACTORY REPRESENTATIVE

A. A qualified factory representative of the piping system shall be present during the

initiation of the buried piping installation, during major field relocations or changes, and

during piping system testing. The factory representative shall supervise the pipe

installation, joint insulation process, and installation of the protective jacket at joints

during the first 2 days of installation. On completion and testing of the work, the

Contractor shall provide a certificate from the manufacturer stating that the installation,

including any field relocation or modifications to the system, has been made in

accordance with the manufacturer's recommendations.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Copper Process Pipe and Tubing



15066 - 1

SECTION 15066

COPPER PROCESS PIPE AND TUBING

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies copper piping, tubing, couplings and fittings.

1.02 REFERENCES















or replaced.

Reference Title

ANSI B16.22 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

ANSI B16.26 Cast Copper Alloy Fittings for Flared Copper Tubes

ASTM B32 Solder Metal

ASTM B88 Seamless Copper Water Tube

1.03 SUBMITTALS

















15066 - 2




PART 2 PRODUCTS

2.01 COPPER TUBING

A. Copper tubing shall be seamless copper, conforming to ASTM B88. Unless otherwise

specified, copper tubing shall be Type L, drawn, where used in exposed service and Type

K, annealed or drawn for buried service.

2.02 COUPLINGS AND FITTINGS FOR COPPER TUBING

A. Unless otherwise specified, couplings and fittings for copper tubing 1/2 inch and smaller

nominal diameter shall be compression type, brass or bronze, capable of holding the full

bursting strength of the tubing; shall meet the requirements of ANSI B16.26; and shall

be Swagelok, Gyrolok, or equal.

B. Couplings and fittings for copper tubing larger than 1/2-inch nominal diameter shall be

wrought copper or bronze, solder joint pressure fittings and shall conform to ANSI

B16.22.

2.03 SOLDER

A. Solder to be used in copper piping shall be ASTM B32, Alloy Grade Sn95 or Silvabrite

100.

2.04 PRODUCT DATA

A. Contractor's layout drawings and catalog data demonstrating compliance with this

specification and giving full description of the copper piping shall be provided in


PART 3 PART 3--EXECUTION

3.01 FABRICATION

A. Solder Joints:

1. All pipe and fittings to be jointed with solder shall be free from all burrs and wire

brushed or steel wool cleaned. After cleaning, a paste flux shall be evenly and

sparingly applied to the surfaces to be joined. Solder shall then be applied and

flame passed toward the center of the fitting until the solder disappears. All excess

solder shall be removed while it is still plastic. Absolutely no acid flux or acid wipe

shall be used in making solder joints.

B. Takedown Couplings:

1. Takedown couplings shall be screw union type and shall be provided in accordance

with Section 15085.




15066 - 3

C. Dielectric Protection:

1. Copper tubing or fittings shall not be permitted to come in contact with steel piping,

reinforcing steel, or other steel at any location. Electrical checks shall be made to

assure no contact is made between copper tubing and steel elements. Wherever

electrical contact is demonstrated by such tests, the Contractor shall provide

dielectric protection as specified in Section 15085.

3.02 INSTALLATION, CLEANING, DISINFECTION, AND TESTING

A. The installation, cleaning, disinfection, and testing of copper piping shall be as specified

in Section 15050.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Joint Gaskets



15075 - 1

SECTION 15075

JOINT GASKETS

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies rubber gaskets for push-on compression type joints used with

fabricated steel pipe, steel pipe, reinforced concrete pipe, concrete cylinder pipe, and

cement mortar lined and coated steel pipe.


A. References:

















Reference Title

ASTM D395 Rubber Property--Compression Set, Test for

ASTM D412 Rubber Properties in Tension, Test for

ASTM D471 Rubber Property--Effect of Liquids, Test for

ASTM D573 Rubber--Deterioration in an Air Oven, Test for

ASTM D1149 Rubber Deterioration--Surface Ozone Cracking in a Chamber (Flat

Specimens), Test for

ASTM D1418 Standard Practice for Rubber and Rubber Latices

ASTM D2240 Rubber Property--Durometer Hardness, Test for

B. Testing:

1. Certified copies of test reports indicating that the gasket material has been tested

and that the results of the tests comply with the requirements specified in paragraph

2.02 shall be provided as product data.




15075 - 2

PART 2 PRODUCTS

2.01 MATERIALS

A. Gasket stock shall be a synthetic rubber compound in which the elastomer is neoprene.

The compound shall contain no less than 50 percent by volume neoprene and shall be

free from factice, reclaimed rubber and other deleterious substances.

B. Unless otherwise specified, all gaskets shall be FKM or Viton.

C. See Section 15050 for piping system specific gasket requirements.

2.02 PHYSICAL REQUIREMENTS

A. The compound shall meet the following physical requirements when tested in

accordance with the specified ASTM standards.

B. Tensile (ASTM D412):

1. The tensile strength shall be 1500 psi minimum and the ultimate elongation shall be

350 percent minimum.

C. Hardness (ASTM D2240, TYPE A DUROMETER):

1. The compound shall have a hardness in the range of 35 to 50 for concrete spigots

and 50 to 65 for steel spigots.

D. Compression Set (ASTM D395):

1. The compression set shall not exceed 20 percent when compressed for 22 hours at

70 degrees C.

2. The test specimens shall be circular discs cut from the gaskets. Test specimens shall

be 0.500 (+ 0.005 - 0.025) inches in height. The diameter of the test specimen shall

be that of the gasket but not to exceed 1.129 + 0.010 inches in diameter.

E. Aging (ASTM D573):

1. The test specimen deterioration shall be less than 20 percent reduction in tensile

strength, 40 percent reduction in ultimate elongation, and 15 points increase in

hardness.

F. Effect Of Liquids (ASTM D471):

1. The maximum volume change in oil and in water shall be as follows:

a. Oil: 100 percent in ASTM oil No. 3.

b. Water: 15 percent.

2. The test specimens shall have a thickness of 0.080 +0.005 inches and shall be

circular discs cut from the gasket.

G. Ozone Cracking (ASTM D1149):

1. The test specimen shall be a gasket loop mounted to give at least 20 percent

elongation. There shall be no cracking visible at two times magnification of the

gasket after 100 hours exposure to 1 mg/l ozone at 40 degrees C.




15075 - 3

2.03 PRODUCT DATA

A. In accordance with Section 01330, the Contractor shall provide certified copies of test

reports specified in paragraph 1.02 Testing.

PART 3 EXECUTION

3.01 INSTALLATION

A. The gaskets shall be installed in accordance with the manufacturer's recommendations.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Piping Connections



15085 - 1

SECTION 15085

PIPING CONNECTIONS

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies the following methods of connecting metallic piping: flanges,

threading, mechanical couplings, equipment connection fittings, dielectric unions, and

welding.

1.02 REFERENCES















or replaced.

Reference Title

ANSI Bl.1 Unified Inch Screw Threads (UN and UNR Thread

Form)

ANSI Bl.20.1 Pipe Threads, General Purpose (Inch)

ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings


ANSI B18.2.1 Square and Hex Bolts and Screws Inch Series

ANSI B18.2.2 Square and Hex Nuts (Inch Series)

ANSI B31.1 Power Piping

ANSI B31.3 Chemical Plant and Petroleum Refinery Piping

ASME Section IX Boiler and Pressure Vessel Code; Welding and

Brazing Procedures, Welders, Brazers, and

Welding and Brazing Operators Qualifications

ASTM B98 Copper-Silicon Alloy Rod, Bar and Shapes

ASTM F37 Standard Test Methods for Sealability of Gasket

Materials

ASTM F104 Standard Classification System for Nonmetallic

Gasket Materials

ASTM F152 Standard Test Methods for Tension Testing of

Nonmetallic Gasket Materials




15085 - 2

Reference Title

ASTM F593 Stainless Steel Bolts, Hex Cap Screws, and

Studs

AWWA C111 Rubber-Gasket Joints for Ductile-Iron Pressure

Pipe and Fittings


AWWA C207 Steel Pipe Flanges for Waterworks Service-Size

4 in. through 144 in.

AWWA C219 Bolted, Sleeve-Type Couplings for Plain-End Pipe

AWWA C550 Protective Epoxy Coatings for Valves and

Hydrants

AWWA C606 Grooved and Shouldered Joints

AWWA M11 Steel Pipe-A Guide for Design and Installation

NSF 61 Drinking Water System Components - Health

Effects

1.03 SUBMITTALS

A. In addition to the material listed in the detailed specification, the following submittals

shall be provided in accordance with Section 01330:

1. For Equipment Connection Fittings used in pumping applications submit thrust rod

stretch calculations in accordance with paragraph 2.02 Equipment Connection

Fittings. and dimensional layout data.

PART 2 PRODUCTS

2.01 FLANGE ASSEMBLIES

A. Flanges:

1. General: Flanges shall either be flat flanges or convoluted ring flanges as specified in

the following paragraphs.

2. Flat Flanges: Cast iron flanges shall be faced in accordance with ANSI B16.1. Where

companion flanges are used, the flanges on pipe shall be refaced to be flush with the

companion flange face. Class 150 and Class 300 forged steel flanges shall be raised

face conforming to ANSI B16.5. Lightweight slip-on flanges shall be plain face

conforming to AWWA C207, Class B and ANSI B16.5. Unless otherwise specified,

steel flanges shall be ANSI B16.5, Class 150 or AWWA C207, Class D. Class E AWWA

flanges shall be provided where test pressure exceeds 175 psi. Plain faced flanges

shall not be bolted to raised face flanges.

3. Convoluted Ring Flanges: Convoluted ring flanges shall be ductile iron, forged steel or

cast stainless steel, designed to bear on hubs welded to the pipe and shall be as

manufactured by Improved Piping Products. The Construction Manager knows of no

equal. The flange joints shall be rated for not less than 150 percent of the test

pressures listed in Section 15050 and shall conform to the requirements of ANSI B

16.5 and AWWA C207. The flange manufacturer shall be prepared to demonstrate,

by certified pressure test that the flanges will meet these requirements.




15085 - 3

B. Gaskets:

1. Gasket material shall be as specified in paragraph 2.03.

2. Gaskets for plain faced flanges shall be the full face type. Thickness shall be 1/16

inch for pipe 10 inches and less in diameter and 1/8 inch for pipe 12 inches and

larger in diameter. Unless otherwise specified, gaskets for raised face flanges shall

match the raised face and shall be 1/16 inch thick for pipe 3-1/2 inches and less in

diameter and 1/8 inch thick for pipe 4 inches and larger.

C. Bolts:

1. Flange assembly bolts shall be ANSI B18.2.1 standard square or hexagon head bolts

with ANSI B18.2.2 standard hexagon nuts. Threads shall be ANSI Bl.1, standard

coarse thread series; bolts shall be Class 2A, nuts shall be Class 2B. Bolt length shall

conform to ANSI B16.5.

2. Unless otherwise specified, bolts shall be carbon steel machined bolts with hot

pressed hexagon nuts. Bolts for submerged service shall be made of Type 316

stainless steel in conformance with ASTM F593, marking F593F. Nuts for submerged

service shall be made of copper-silicon alloy bronze conforming to ASTM B98, alloy

C65100, designation H04 or alloy C65500, designation H04. Bolts and nuts for

buried service shall be made of noncorrosive high-strength, low-alloy steel having the

characteristics specified in ANSI/AWWA C111/A21, regardless of any other

protective coating. Where washers are required, they shall be of the same material

as the associated bolts.

2.02 MECHANICAL COUPLINGS

A. Dismantling Joints:

1. Dismantling joints may be used as takedown couplings in accordance with paragraph

3.03. Dismantling joints shall fully restrained double flange fittings consisting of a

flange coupling adapter and flanged spool piece that allows for longitudinal

adjustment. Thrust restraint shall be provided by means of all threaded rod spanning

between flanges and secured to the flanges with a minimum of two flange bolts.

Design of equipment connection fittings shall conform to AWWA C219. Sleeves shall

be carbon steel or as specified for the specific piping system. Pressure rating of

flange adapters shall equal or exceed the pressure rating of mating flanges. All metal

portions of equipment connection fittings, with the exception of 316 stainless steel

components, shall be coated and lined with fusion bonded epoxy conforming to

AWWA C550 and NSF 61. Dismantling joints shall be Romac DJ-400, Smith Blair

975, or Crane-Viking Johnson Dismantling Joint.

2.03 GASKETS

A. Gaskets designated in Section 15050 shall be as follows:

1. FKM / Viton: fluoro-elastomer.

2. EPDM: ethylene-propylene-diene-terpolymer.

3. Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder;

ASTM F104 (F712400), 2500 psi (ASTM F152), 0.2 ML/HR LEAKAGE FUEL A (ASTM

F37).

4. Compressed gasketing consisting of organic fibers (Kevlar) and SBR binder; ASTM

F104 (F712400), 2500 PSI (ASTM F152), 0.1 ml/hr leakage Fuel A (ASTM F37).




15085 - 4

5. Gylon gasketing, Garlock Style 3500, 2000 psi (ASTM F152), 0.22 ml/hr Fuel A

(ASTM F37).


(ASTM F37).


(ASTM F37).

8. TFE: noncreeping tetrafluoroethylene (TFE) with insert filler.

9. PTFE bonded EPDM: PTFE bonded to EPDM in full-face gasket having concentric-

convex molded rings; Garlock Stress Saver 370 or equal.

2.04 THREAD

A. Pipe thread dimensions and size limits shall conform to ANSI Bl.20.1.

2.05 DIELECTRIC UNIONS

A. Dielectric unions shall be EPCO, Capitol Manufacturing, or equal.

2.06 COATINGS

A. Unless otherwise specified, flange assemblies and mechanical type couplings for buried

installation shall be field coated with System M-1 as specified in Section 09900.

2.07 PRODUCT DATA

A. In accordance with Section 01330, the Contractor shall provide for each welder, a welder

qualification certificate indicating the welder is certified for pipe welding in accordance

with ASME Boiler and Pressure Vessel, Section IX. Each welder's certificate shall be

provided to the Construction Manager prior to that welder working on the job.

PART 3 EXECUTION

3.01 PIPE CUTTING, THREADING AND JOINTING

A. Pipe cutting, threading and jointing shall conform to the requirements of ANSI B31.1.

3.02 PIPE WELDING

A. Pipe shall be welded by ASME-certified welders using shielded metal arc, gas shielded

arc or submerged arc welding methods. Welds shall be made in accordance with the

requirements of ANSI B31.1 for piping Systems 8, 26, and 28 specified in Section

15050.

B. Welds for piping systems not specified above shall be made in accordance with AWWA

C206.




15085 - 5

3.03 TAKEDOWN COUPLINGS

A. Takedown couplings shall be screw unions, flanged or grooved end mechanical coupling

type joints and shall be provided as specified. Flanged or grooved end joints shall be

employed on pipelines 2-1/2 inches in diameter and larger. Where piping passes through

walls, takedown couplings shall be provided within 3 feet of the wall, unless specified

otherwise.

B. A union or flanged connection shall be provided within 2 feet of each threaded end valve.

3.04 FLEXIBILITY

A. Unless otherwise specified, piping passing from concrete to earth shall be provided with

two pipe couplings or flexible joints (or a single Flexijoint) as specified on the buried pipe

within 2 feet of the structure for 2-inch through 6-inch diameter pipe; within 3 feet of the

structure for 8-inch through 24-inch diameter pipe; and within one and one-half pipe

diameters of the structure for larger pipe. Where required for resistance to pressure,

mechanical couplings shall be restrained in accordance with Chapter 13 of AWWA M11,

including Tables 13-4, 13-5 and 13-5A, and Figure 13-20.

3.05 DIELECTRIC CONNECTIONS

A. Where a copper pipe is connected to steel or cast iron pipe, an insulating section of

rubber or plastic pipe shall be provided. The insulating section shall have a minimum

length of 12 pipe diameters. Dielectric unions as specified in paragraph 2.05 may be

used instead of the specified insulating sections. Where copper pipe is supported from

hangers, it shall be insulated from the hangers, or copper-plated hangers shall be used.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Expansion Joints and Flexible Metal Hose



15090 - 1

SECTION 15090

EXPANSION JOINTS AND FLEXIBLE METAL HOSE

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies piping expansion joints.


A. References:

















Reference Title

ASTM A276-90 Stainless and Heat-Resisting Steel Bars and Shapes

EJMA STDS-80 Standards of Expansion Joint Manufacturers' Association,

Edition No. 5

B. Performance and Service Conditions:

1. Expansion joints shall be designed in accordance with EJMA Standards for pressure,

temperature and service as specified.

C. Design Requirements:

1. Expansion Joints: Corrugated type expansion joints shall be suitable for a minimum of

10,000 pressure, temperature and deflection cycles (non-concurrent).

1.03 SUBMITTALS

A. The following submittals shall be provided in accordance with Section 01330:




requested deviations from specification requirements. A check mark ( ) shall




15090 - 2

denote full compliance with a paragraph as a whole. If deviations from the

specifications are indicated, and therefore requested by the Contractor, each

deviation shall be underlined and denoted by a number in the margin to the right of

the identified paragraph, referenced to a detailed written explanation of the reasons

for requesting the deviation. The Construction Manager shall be the final authority for

determining acceptability of requested deviations. The remaining portions of the

paragraph not underlined will signify compliance on the part of the Contractor with

the specifications. Failure to include a copy of the marked-up specification sections,

along with justification(s) for any requested deviations to the specification

requirements, with the submittal shall be sufficient cause for rejection of the entire

submittal with no further consideration.

2. Materials, design and construction, and temperature and pressure rating for

elastomer and fabric expansion joints.

3. Details for installation of all expansion joints.

PART 2 PRODUCTS

2.01 EXPANSION JOINTS

A. Elastomer and Fabric Construction:

1. General: Elastomer and fabric expansion joints shall be the standard spool arch type

or the precision molded spherical design type as indicated or specified. Expansion

joint connectors shall have control units (restraints) to prevent excessive axial

elongation and to accept the static pressure thrust in the piping system. Number and

sizes of control rods or restraints shall be as determined by the manufacturer. Unless

otherwise specified, single arch and sphere type expansion joints shall have 6-inch

face-to-face dimension for pipe up to 8 inches and 8-inch face-to-face dimension for

pipe 10 and 12 inches.

a. The cover elastomer shall be chlorobutyl, neoprene or EPDM. The tube elastomer

shall be FKM (Viton).

2. Spool Type: Spool type expansion joints shall be of the resilient arch type and shall be

standard or tapered as specified. Unless otherwise specified, all tapered connectors

shall be eccentric.

a. Spool type expansion joints shall be constructed of multiple plies of woven fabric

impregnated with elastomer and reinforced with steel rings or wire embedded in

the body. Standard arch type expansion joints suitable for the specified

temperature and pressure shall be provided with retaining rings or backup rings.

Retaining rings shall be 3/8-inch thick steel, split, either galvanized or zinc shield

coated. Expansion joints, single, multiple, or filled arch, shall be Mason Style

EJBN, Garlock Style 204, Mercer Style 500, General Style 1101, or equal. Filled

arch type shall be used on all piping systems carrying fluids containing solids.

High pressure couplings suitable for 240 degree F operating temperatures shall

be Mason Style EJBN-HD, Mercer Style 510, Garlock Style 204-HP, Goodall Style

E-1489, General Style 1015, or equal.

2.02 PRODUCT DATA

A. The following information shall be provided to the Construction Manager in accordance

with Section 01330:

1. Details for installation of all expansion joints.




15090 - 3

PART 3 EXECUTION

3.01 INSTALLATION

A. Expansion joints and anchors shall be located as specified. Location and number of

guides shall be determined from EJMA Standards.

B. Expansion joints shall not be installed during times of temperature extreme or in a fully

compressed or fully expanded condition.

3.02 ALIGNMENT

A. Piping systems shall be aligned prior to installation of expansion joints. Expansion joints

shall not be used to correct piping misalignment during installations. Expansion joints

normally preset at the factory for rated axial compression and expansion shall be

installed in this preset condition.

3.03 EXPANSION JOINT AND CONNECTOR SCHEDULE

A. Expansion joints and/or flexible metal hose connectors provided for specific equipment

items or piping systems are specified on the following schedule. The location of piping

system expansion joints and design criteria, including temperature, pressure and

movement for each joint, are specified on the drawings.

B. Expansion joints and connectors shall be provided in accordance with the following table.

If a particular joint or connector is shown or specified for a given location, that more

detailed selection shall apply.

Expansion Joint and Connector Schedule

Type of Expansion Joint/Connection Type of Service/Use

Spool Type FOG Pump 715P6405 Suction

Spool Type FOG Pump 715P6405 Discharge

Spool Type 6” FOG Pipe between FV6409 and FOG Waste

Storage Tank 2

Spool Type FOG Waste Storage Tank 1 – all shell nozzlesa

Spool Type FOG Waste Storage Tank 2 – all shell nozzlesa

a Refer to drawing M102 for nozzle schedule

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Piping Appurtenances



15095 - 1

SECTION 15095

PIPING APPURTENANCES

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies pipeline strainers, vents and drains.

B. Exclusions:

1. Temperature, pressure and flow measuring devices used for instrumentation are

specified in Division 17.

1.02 REFERENCES















or replaced.

Reference Title

SAMA PMC 17-10 Bushings and Wells for Temperature Sensing Elements

1.03 SUBMITTALS






requested deviations from specification requirements. Check-marks (✓) shall denote

full compliance with a paragraph as a whole. Deviations shall be underlined and

denoted by a number in the margin to the right of the identified paragraph. The

remaining portions of the paragraph not underlined will signify compliance on the

part of the Contractor with the specifications. Include a detailed, written justification

for each deviation. Failure to include a copy of the marked-up specification sections,




15095 - 2

along with justification(s) for any requested deviations to the specification

requirements, with the submittal shall be sufficient cause for rejection of the entire


3. Locate appurtenances on the piping layout drawings by plant area and submit in


4. Manufacturer’s product data.

B. Closeout Submittals:


2. Operating and maintenance submittals: Section 01782.

PART 2 PRODUCTS

2.01 GENERAL

A. Unless otherwise specified or shown on the Drawings:

1. All equipment shall be the same size as adjoining pipe.

2. Body material of appurtenances shall match pipeline material.

3. Pressure rating of appurtenances shall be no less than 150 psi.

B. All units shall have the name of the manufacturer and the size of the unit cast on the

body or shown on a permanently attached plate in raised letters.

C. All equipment provided shall be equipped with flanges, integral unions, or other

functional connections for removal.

2.02 STRAINERS

A. Water Strainers:

1. Unless otherwise indicated, water strainers shall be Y-pattern.

2. Bronze bodies shall be provided with copper piping. Cast iron bodies shall be

provided with steel piping.

3. Strainers shall have 304 stainless steel screens and tapped and plugged blowoff

connections.

4. Screen perforations shall be 0.045 inch.

5. Acceptable manufacturers:

a. Mueller.

b. Armstrong.

c. Or Approved equal.

2.03 QUICK CONNECT FITTINGS

A. Air and water utility station quick connect fittings.

1. Acceptable manufacturers:

a. Dixon Air King.

b. Chicago Pneumatic.





15095 - 3

B. All other quick connect fittings:

Type: Coupler type, with cam arms. Capable of connecting to a hose adapter without

the use of tools.

Size: The same size as the pipeline.

Materials: PVDF with Teflon gaskets.

Acceptable manufacturers:

a. Kamlock.

b. Chicago Pneumatic.


PART 3 EXECUTION

3.01 GAGE TAPS

A. Provide gage taps on the suction and discharge of pumps, fans, compressors, vacuum

pumps and blowers.

B. Gage taps for water and air service shall consist of a 1/4-inch gage cock attached by a

threaded nipple to the pipeline, duct or equipment.

3.02 VENTS AND DRAINS

A. Vents:

1. Provide manual air vents at the high points of each reach of pipeline shown on the

drawings, and provide additional manual drains as required and specified by the

Project Representative after completion of piping installation.

2. Provide manual air vents between all double block valves, as indicated on the

drawings.

3. Air vents shall be 1-inch and shall consist of full port ball valve and copper tubing

return.

4. Air vents shall be taken to the nearest floor with ball valve mounted 4 feet above the

floor.

5. Fit vents in piping systems for fluids containing solids with quick couplers.

B. Drains:

1. Pipe each drain to a sump, gutter, floor drain or other collection point with a valve

mounted 4 feet above the floor.

2. Drain valves in piping systems for fluids containing solids shall be threaded end full

port plug valves of the size specified, fitted with quick couplers. All other drain valves

shall be threaded end gate valves of the size specified, fitted with quick couplers.

3. When a drain cannot be run to a collection point, route the drain to a point of easy

access and install a valve, of the type and size specified, fitted with a male threaded

nipple suitable for connection to a hose.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Hangers and Supports for Process Piping



15096 - 1

SECTION 15096

HANGERS AND SUPPORTS FOR PROCESS PIPING

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies hangers and supports for all piping systems specified in

Section 15050. This section does not include pipe supports for fire sprinkler

systems, pipe anchors, guides or seismic restraints.

B. Operating Conditions:

1. The hangers and supports specified in this section are provided to resist pipe loads

occurring primarily in the downward (gravity) direction. For the purpose of pipe

hanger and support selection, this section establishes pipe support classifications

based on the operating temperatures of the piping contents. Pipe support

classifications are as follows:

a. Hot Systems

1) A - 1. 120 degrees F to 450 degrees F

2) A - 2. 451 degrees F to 750 degrees F

3) A - 3. Over 750 degrees F

b. Ambient Systems

1) B. 60 degrees F to 119 degrees F

c. Cold Systems

1) C - 1. 33 degrees F to 59 degrees F

2) C - 2. -20 degrees F to 32 degrees F

C. Hanger and Support Selection:

1. The Contractor shall select pipe hangers and supports as specified in the project

manual. Selections shall be based upon the pipe support classifications specified in

this section, the piping insulation thickness specified in Section 15250, and any

special requirements which may be specified in the project manual.

2. The Contractor shall review the piping layout in relation to the surrounding structure

and adjacent piping and equipment before selecting the type of support to be used at

each hanger point.

3. Hangers and supports shall withstand all static and specified dynamic conditions of

loading to which the piping and associated equipment may be subjected. As a

minimum, consideration shall be given to the following conditions:

a. Weights of pipe, valves, fittings, insulating materials, suspended hanger

components, and normal fluid contents.

b. Weight of hydrostatic test fluid or cleaning fluid if normal operating fluid contents

are lighter.

c. Reaction forces due to the operation of safety or relief valves.

d. Wind, snow or ice loadings on outdoor piping.




15096 - 2

4. Hangers and supports shall be sized to fit the outside diameter of pipe, tubing, or,

where specified, the outside diameter of insulation.

5. Where negligible movement occurs at hanger locations, rod hangers shall be used for

suspended lines, wherever practical. For piping supported from below, bases,

brackets or structural cross members shall be used.

6. Hangers for the suspension of size 2 1/2 inches and larger pipe and tubing shall be

capable of vertical hanger component adjustment under load.

7. The supporting systems shall provide for and control the free or intended movement

of the piping including its movement in relation to that of connected equipment.

8. Where there is horizontal movement at a suspended type hanger location, hanger

components shall be selected to allow for swing. The vertical angle of the hanger rod

shall not, at any time, exceed 4 degrees.

9. There shall be no contact between a pipe and hanger or support component of

dissimilar metals. Prevent contact between dissimilar metals when supporting copper

tubing by use of copper-plated, rubber, plastic or vinyl coated, or stainless steel

hanger and support components.

10. Unless otherwise specified, existing pipes and supports shall not be used to support

new piping.

11. Unless otherwise specified, pipe support components shall not be attached to

pressure vessels.

12. Stock hanger and support components shall be used wherever practical.

1.02 REFERENCES















or replaced.

Reference Title

AISC Manual of Steel Construction American Institute of Steel Construction, Manual of Steel

Construction, Allowable Stress Design - 9th Ed.

FEDSPEC WW-H-171e-78 Hangers and Supports, Pipe

MFMA-2-91 Metal Framing Standards Publication

MSS SP-69-91 Pipe Hangers and Supports - Selection and Application

MSS SP-58-93 Pipe Hangers and Supports - Materials, Design and Manufacture




15096 - 3

PART 2 PRODUCTS


A. Standard pipe supports and components shall be manufactured by B-Line, Carpenter &

Patterson, Kin-Line, Anvil, Michigan, Pipe Shields Incorporated, Superstrut, Unistrut, or

equal. Pipe support components shall conform to the requirements of MSS SP-69 and

FEDSPEC WW-H-171e. Pipe support materials shall conform to the requirements of MSS

SP-58. Metal framing system components shall conform to the metal framing

manufacturers' Association Standard MFMA-2.

2.02 MATERIALS

A. General:

1. Unless otherwise specified, pipe hangers and supports, structural attachments,

fittings and accessories shall be hot-dip or mechanically galvanized after fabrication.

Nuts, bolts and washers shall be type 304 stainless steel.

B. Pipe Hangers and Supports:

1. Type 1 - Clevis Pipe Hanger: Clevis hangers shall be carbon steel with configuration

and components equivalent to MSS and FEDSPEC Type 1.

a. Cast and ductile iron pipe - shall be B-Line B3102, Anvil Fig. 590, or equal.

b. Copper pipe (uninsulated) - shall be B-Line B3104 CT, Anvil Fig. CT-65, or equal.

c. Copper pipe (insulated) - shall be B-Line B3100, Anvil Fig. 260, or equal, with

insulation shield.

d. Plastic pipe - shall be B-Line B3100 C, Carpenter & Patterson Fig. 100PVC, or

equal.

2. Type 6 - Framing Channel Pipe Clamp: Pipe clamps shall be steel with galvanized

finish and material thickness as listed below:

a. Copper (uninsulated) and plastic pipe - Pipe size 3/8 inch and 1 inch shall be 16

gage; 1-1/4 inches and 1-1/2 inches shall be 14 gage; 2 inches through 3 inches

shall be 12 gage; 4 inches shall be 11 gage; clamp shall be copper-plated, plastic

coated or lined with dielectric material; Michigan model 432, Powerstrut PS

1200, Unistrut P 2024C and P 2024PC series, or equal.

b. Copper pipe (insulated) - Pipe clamp shall be as described in

paragraph 2.02 Steel Pipe (Uninsulated) with insulation shield.

3. Type 7 - U-BOLT: U-bolts shall be carbon steel with configuration equivalent to MSS

and FEDSPEC Type 24.

a. Cast and ductile iron pipe - shall be Anvil Fig. 137, B-Line B3188, or equal.

b. Copper pipe (uninsulated) - shall be Carpenter & Patterson Fig. 222 CT, B-Line

B3501 CT, Anvil Fig. 137C, or equal.

c. Copper pipe (insulated) - shall be Anvil Fig. 137, B-Line B3188, or equal, with

insulation shield.

d. Plastic pipe - shall be Anvil Fig. 137C, Michigan model 151, B-Line B3188 C, or

equal.

4. Type 9 - Welded Pipe Stanchion: Minimum material thickness shall be standard

schedule carbon steel pipe, cut to match contour of the pipe elbow. Use of this

support shall be limited to ambient systems only.




15096 - 4

5. Type 10 - Pipe Stanchion Saddle: Saddles and yokes shall be carbon steel and

comply with MSS Type 37 and FEDSPEC Type 38.

a. Cast and ductile iron pipe - shall be Carpenter & Patterson Fig. 125, B-Line

B3090 NS, or equal.

b. Copper pipe (uninsulated) - shall be Carpenter & Patterson Fig. 125, B-Line

B3090, or equal, with insulation shield or lined with dielectric material.

c. Copper pipe (insulated) - shall be Carpenter & Patterson Fig. 125, B-Line B3090,

or equal, with insulation shield.

d. Plastic pipe - shall be Carpenter & Patterson Fig. 125, B-Line B3090, or equal.

6. Type 11 - Offset Pipe Clamp: Pipe clamp shall be carbon steel with configuration and

components as specified and shall be of standard design manufactured by a pipe

hanger component manufacturer.

a. Cast and ductile iron pipe - shall be B-Line B3148 NS, Anvil Fig. 103, or equal.

b. Copper pipe (insulated) - shall be B-Line B3148, Anvil Fig. 103, or equal, with

insulation shield.

c. Copper pipe (uninsulated) - shall be B-Line B3148, Anvil Fig. 103, or equal, lined

with dielectric material.

d. Plastic pipe - shall be B-Line B3148, Anvil Fig. 103, or equal.

e. Vertical pipe support applications shall be as specified above except that

insulation shields shall not be used for insulated pipe.

7. Type 12 - Riser Clamp: Riser clamp shall be carbon steel with configuration and

components equivalent to MSS and FEDSPEC Type 8.

a. Steel pipe (insulated) - shall be B-Line B3373, Anvil Fig. 261, or equal.

b. Steel pipe (uninsulated) - shall be B-Line B3373, Anvil Fig. 261, or equal.

c. Cast and ductile iron pipe - shall be B-Line B3373, Anvil Fig. 261, or equal.

d. Copper pipe (insulated) - shall be B-Line B3373 CT, Anvil Fig. CT-121, Michigan

model 511, or equal.

e. Copper pipe (uninsulated) - shall be B-Line B3373 CT, Anvil Fig. CT-121, Michigan

model 511, or equal.

f. Plastic pipe - shall be B-Line B3373, Anvil Fig. 261c, or equal.

8. Type 13 - Framing Channel Pipe Strap: Pipe strap shall be carbon steel, with

configuration equivalent to MSS Type 26.

a. Copper pipe (uninsulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126,

Kin-Line No. 477, or equal, with insulation shield or lined with dielectric material.

b. Copper pipe (insulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126,

Kin-Line No. 477, or equal, with insulation shield.

c. Plastic pipe - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No.

477, or equal.




15096 - 5

C. Structural Attachments:

1. Type E - Framing Channel Post Base: Post bases shall be carbon steel, of standard

design manufactured by framing channel manufacturer. Single channel: Unistrut

P2072A, B-Line B280, or equal. Double channel: Unistrut P2073A, B-Line B281, or

equal.

2. Type G - Welded Steel Bracket: Bracket shall be carbon steel and comply with MSS

Type 32 and FEDSPEC Type 33 for medium welded bracket. Heavy welded bracket

shall comply with MSS Type 33 and FEDSPEC Type 34.

3. Type J - Adjustable Beam Attachment: Beam attachment shall be carbon steel,

Carpenter & Patterson Fig. 151, B-Line B3082, or equal.

4. Type K - Double Channel Bracket: Wall channel shall be single channel framing

channel as specified in paragraph 2.02 Framing Channel. Cantilever bracket shall be

a carbon steel double framing channel assembly, Unistrut P2542 through P2546, B-

Line B297-12 through B297-36, or equal.

5. Type L - Single Channel Bracket: Wall channel shall be single channel framing

channel as specified in paragraph 2.02 Framing Channel. Cantilever bracket shall be

a carbon steel single framing channel assembly, Unistrut P2231 through P2234, B-

Line B198-6, B198-12, B196-18 and B196-24, or equal.

6. Type M - Wall Mounted Channel: Wall channel shall be single channel framing

channel as specified in paragraph 2.02 Framing Channel.

7. Type N - Pipe Stanchion Floor Attachment: Baseplate shall be carbon steel with 1/2

inch minimum thickness. Anchor bolt holes shall be 1/16 inch larger than the anchor

bolt diameter. The space between the baseplate and the floor shall be filled with

nonshrink grout.

8. Type P – Concrete Single Lug Plate: Baseplate shall be carbon steel with 3/4 inch

minimum thickness. Anchor bolt holes shall be 1/16 inch larger than the anchor bolt

diameter. Lug shall be continuously welded to base plate.

D. Accessories:

1. Hanger Rods: Rods shall be carbon steel, threaded on both ends or continuous

threaded and sized as specified.

2. Weldless Eye Nut: Eye nut shall be forged steel and shall comply with MSS and

FEDSPEC Type 17. Eye nut shall be Anvil Fig. 290, B-Line B3200, or equal.

3. Welded Eye Rod: Eye rod shall be carbon steel with eye welded closed. Inside

diameter of eye shall accommodate a bolt diameter 1/8 inch larger than the rod

diameter. Eye rod shall be Anvil Fig. 278, B-Line B3211, or equal.

4. Turnbuckle: Turnbuckle shall be forged steel and shall comply with MSS and

FEDSPEC Type 13. Turnbuckle shall be Anvil Fig. 230, B-Line B3202, or equal.

5. Framing Channel: Framing channel shall be 1 5/8 inches square, roll formed, 12-

gage carbon steel. Channel shall have a continuous slot along one side with in-turned

clamping ridges. Single channel: Unistrut P1000, B-Line B22, or equal. Double

channel: Unistrut P1001, B-Line B22A, or equal. Triple channel: Unistrut P1004A, B-

Line B22X, or equal.




15096 - 6

2.03 THERMAL PIPE HANGER SHIELD

A. Thermal shields shall be provided at hanger, support and guide locations on pipe

requiring insulation. The shield shall consist of an insulation layer encircling the entire

circumference of the pipe and a steel jacket encircling the insulation layer. The thermal

shield shall be the same thickness as the piping system insulation specified in Section

15250. The standard shield shall be used for hot systems and the vapor barrier shield

shall be used for cold systems. Stainless steel band clamps shall be used where

specified to ensure against slippage between the pipe wall and the thermal shield.

B. Standard Shield:

1. Insulation:

a. Hydrous calcium silicate, high density, waterproof

b. Compressive strength: 100 psi average

c. Flexural strength: 75 psi average

d. K factor: 0.38 at 100 degrees F mean

e. Temperature range: 20 degrees F to 500 degrees F

2. Steel Jacket: Galvanized steel. Gage shall be the manufacturer's standard supplied

for the given pipe size.

3. Connection: Shield shall have butt connection to pipe insulation. Steel jacket and

insulation shall be flush with end.

C. Vapor Barrier Shield:

1. Insulation:

a. Hydrous calcium silicate, high density, waterproof

b. Compressive strength: 100 psi average

c. Flexural strength: 75 psi average

d. K factor: 0.38 at 100 degrees F mean

e. Temperature range: 20 degrees F to 500 degrees F

2. Steel Jacket: Galvanized steel. Gage shall be the manufacturer's standard supplied

for the given pipe size.

3. Connection: Shield shall have butt connection to pipe insulation. Insulation shall

extend 1 inch each side of steel jacket for vaportight connection to pipe insulation

vapor barrier.

2.04 PRODUCT DATA

A. Hanger and support locations and components shall be indicated on the piping layout

drawings required by Section 15050-1.03 and -2.04.




15096 - 7

PART 3 EXECUTION

3.01 HANGER AND SUPPORT LOCATIONS

A. The Contractor shall locate hangers and supports as near as possible to concentrated

loads such as valves, flanges, etc. Locate hangers, supports and accessories within the

maximum span lengths specified in the project manual to support continuous pipeline

runs unaffected by concentrated loads.

B. At least one hanger or support shall be located within 2 feet from a pipe change in

direction.

C. The Contractor shall locate hangers and supports to ensure that connections to

equipment, tanks, etc., are substantially free from loads transmitted by the piping.

D. Where piping is connected to equipment, a valve, piping assembly, etc., that will require

removal for maintenance, the piping shall be supported in such a manner that temporary

supports shall not be necessary for this procedure.

E. Pipe shall not have pockets formed in the span due to sagging of the pipe between

supports caused by the weight of the pipe, medium in the pipe, insulation, valves and

fittings.

3.02 INSTALLATION

A. Welded and bolted attachments to the building structural steel shall be in accordance

with the requirements of the AISC Manual of Steel Construction. Unless otherwise

specified, there shall be no drilling or burning of holes in the building structural steel.

B. Hanger components shall not be used for purposes other than for which they were

designed. They shall not be used for rigging and erection purposes.

C. The Contractor shall install items to be embedded before concrete is poured. Fasten

embedded items securely to prevent movement when concrete is poured.

D. Embedded anchor bolts shall be used instead of concrete inserts for support installations

in areas below water surface or normally subject to submerging.

E. The Contractor shall install thermal pipe hanger shields on insulated piping at required

locations during hanger and support installation. Butt joint connections to pipe insulation

shall be made at the time of insulation installation in accordance with the manufacturer's

recommendations.

F. Hanger and support components in contact with plastic pipe shall be free of burrs and

sharp edges.

G. Rollers shall roll freely without binding.

H. Finished floor beneath Type N structural attachments and framing channel post bases

shall be roughed prior to grouting. Grout between base plate and floor shall be free of

voids and foreign material.




15096 - 8

I. Baseplates shall be cut and drilled to specified dimensions prior to welding stanchions or

other attachments and prior to setting anchor bolts.

J. Plastic or rubber end caps shall be provided at the exposed ends of all framing channels

that are located up to 7 feet above the floor.

3.03 ADJUSTMENTS

A. The Contractor shall adjust hangers and supports to obtain required pipe slope and

elevation. Shims made of material that is compatible with the piping material may be

used. Stanchions shall be adjusted prior to grouting their baseplates.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Seismic Restraints For Piping



15097 - 1

SECTION 15097

SEISMIC RESTRAINTS FOR PIPING

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies seismic restraints for bracing all piping systems specified in

Section 15050. This section does not include seismic restraints for fire sprinkler

systems.

B. Definitions:

1. Longitudinal direction--direction parallel to the pipe axis.

2. Lateral direction--direction perpendicular to the pipe axis.

C. Operating Conditions:

1. The seismic restraints specified in this section are provided to resist pipe movements

and loads occurring as a result of an earthquake or other seismic event.

2. Unless otherwise specified, all piping shall have bracing to resist seismic loading

caused by forces applied at the individual pipe's center of gravity. Seismic loading

shall be 0.32 g acting in the lateral and longitudinal directions and 0.17 g acting

simultaneously in the vertical directions.

D. Restraint Selection:

1. Unless otherwise specified, the Contractor shall select, locate and provide seismic

restraints for piping in accordance with the project manual.

2. The Contractor shall review the piping layout in relation to the surrounding structure

and adjacent piping and equipment before selecting the restraint to be used at each

point.

3. Seismic restraints may be omitted from the following installations:

a. Gas piping less than 1-inch inside diameter.

b. Piping in boiler and mechanical rooms less than 1 1/4-inch inside diameter.

c. All other piping less than 2 1/2-inch inside diameter.

d. All piping suspended by individual hangers 12 inches or less in length from the

top of the pipe to the bottom of the support for the hanger.

4. Piping systems shall not be braced to dissimilar parts of a building or to dissimilar

building systems that may respond in a different mode during an earthquake.

Examples: wall and a roof; solid concrete wall and a metal deck with lightweight

concrete fill.

5. Restraints shall be sized to fit the outside diameter of the pipe, tubing, or, where

specified, the outside diameter of insulation.

6. There shall be no contact between a pipe and restraint component of dissimilar

metals. The contractor shall prevent contact between dissimilar metals when

restraining copper tubing by the use of copper-plated, rubber, plastic or vinyl coated,

or stainless steel restraint components.




15097 - 2

7. Branch lines shall not be used to brace main lines.

8. Seismic bracing shall not limit the expansion and contraction of the piping system.


A. References:

















Reference Title

ANSI A58.1-82 Minimum Design Loads for Buildings and Other Structures

AISC Manual of Steel Construction American Institute of Steel Construction, Manual of Steel

Construction, Allowable Stress Design - 9th Edition

FEDSPEC WW-H-171e-78 Hangers and Supports, Pipe

MFMA-2-91 Metal Framing Standards Publication

MSS SP-58-93 Pipe Hangers and Supports - Materials, Design and

Manufacture

MSS SP-69-91 Pipe Hangers and Supports - Selection and Application

SMACNA, PPIC Guidelines for Seismic Restraints of Mechanical Systems

and Plumbing Piping Systems

1.03 SUBMITTALS

















15097 - 3

3. Locations of hangers, supports and restraints on piping layout drawings as specified

in Section 15050.



B. Approval:

1. Seismic restraint load calculations specified in paragraph 3.01 shall be reviewed and

signed by a structural engineer registered in the State of Oregon.

PART 2 PRODUCTS


A. Standard pipe restraints and components shall be manufactured by Carpenter &

Patterson, B-Line, Kin-Line, ITT Grinnell, Michigan, Pipe Shields Incorporated, Superstrut,

Unistrut, or equal. Pipe restraint materials shall conform to the requirements of MSS SP-

58 and MFMA-1.

2.02 MATERIALS

A. General:

1. Unless otherwise specified, restraints, including braces, pipe and structural

attachments, shall be hot-dip galvanized after fabrication. Nuts, bolts and washers,

fittings and accessories, may be mechanically zinc-coated except for those subject to

moisture or corrosive atmosphere, which shall be type 304 stainless steel.

B. Pipe Attachments:

1. Type 1s: Clevis Restraint Attachment: Clevis attachment shall be Type 1, clevis pipe

hanger, as specified in Section 15096-2.02 Pipe Hangers and Supports.

C. Braces and Fittings:

1. Seismic Brace Fitting: Seismic brace fitting shall be manufactured for use with

industry standard framing channel. The fitting shall be carbon steel, welded

construction, two-piece linked fitting. A means to reduce noise and vibration

transmission between the linked fitting parts shall be provided. Seismic brace fittings

shall be Superstrut C-749N series seismic brace, Kin-Line No. 633 seismic connector

fitting, or equal.

2. Hanger Rod Stiffener Assembly: Rod stiffener channel shall be 1 5/8-inch square

carbon steel framing channel, Unistrut P1000, B-Line B22, Superstrut A-1200, or

equal. Rod stiffener clamps shall be complete with channel nut and shall be

Superstrut ES-142, Kin-Line No. 635, or equal.

3. Type A1 Seismic Brace: Seismic brace shall be 1 5/8-inch square carbon steel

framing channel, Unistrut P1000, B-Line B22, Superstrut A-1200, Kin-Line No. 4112,

or equal.

4. Type A2 Seismic Brace: Seismic brace shall be 1 5/8-inch wide by 3 1/4-inch deep

carbon steel framing channel, Unistrut P5000, B-Line B11, Superstrut H-1200, Kin-

Line No. 8212, or equal.




15097 - 4

D. Structural Attachments:

1. General: Unless otherwise specified, hanger rod structural attachments shall be as

specified in Section 15096. Structural attachments for longitudinal and lateral

seismic braces shall be as specified in paragraph 2.02 Structural Attachments.

2. Type SA-1 Attachment: Brace fitting shall be as specified in paragraph 2.02 Braces

and Fittings. Concrete anchors shall be as specified in Section 05502 with

embedment and location dimensions as specified.

3. Type SA-2 Attachment: Brace fitting shall be as specified in paragraph 2.02 Braces

and Fittings. Concrete anchors shall be as specified in Section 05502 with

embedment and location dimensions as specified. Framing channel shall be as

specified in paragraph 2.02 Accessories.

E. Accessories:

1. Hanger Rods: Rods shall be carbon steel, threaded on both ends or continuous

threaded and sized as specified.

2. Framing Channel: Framing channel shall conform to the Metal Framing

Manufacturers Association standard MFMA-1. Framing channel shall be roll formed,

12-gage carbon steel. Channel shall have a continuous slot along one side with in-

turned clamping ridges. Channel shall be Unistrut P1000 series, B-Line B22 series,

Superstrut A-1200 series, or equal.

3. Rod Coupling: Rod coupling shall be carbon steel, with sight hole in center of coupling

body, Grinnell Fig. 135, Superstrut H-119, or equal.

2.03 THERMAL PIPE HANGER SHIELD

A. Thermal shields shall be provided at seismic restraint locations on pipe requiring

insulation. Thermal pipe hanger shields shall be as specified in Section 15096-2.03.

Stainless steel band clamps shall be provided on thermal shields at longitudinal pipe

restraint locations.

2.04 PRODUCT DATA

A. The following information shall be provided as specified in Section 01330:

1. Seismic restraint locations and legend as specified in paragraph 3.01.

2. Load calculations as specified in paragraph 1.03 Approval.

PART 3 EXECUTION

3.01 PIPE RESTRAINT LOCATIONS

A. The first seismic restraint on a piping system shall be located not more than 10 feet from

the main riser, entrance to a building or piece of equipment.

B. Cast iron pipe shall be braced on each side of a change in direction of 90 degrees or

more. Joints in risers shall be braced or stabilized between floors.

C. No-hub and bell and spigot cast iron soil pipe shall be braced longitudinally every 20 feet

and laterally every 10 feet.




15097 - 5

D. Lateral bracing for one pipe section may also act as longitudinal bracing for the pipe

section connected perpendicular to it, if the bracing is installed within 24 inches of the

elbow or tee of the same size.

E. Seismic restraint locations and components shall be indicated on the piping layout

drawings required by Section 15050-2.04. The Contractor shall provide a legend giving

load information and restraint component selection at each restraint location.

3.02 INSTALLATION

A. Rod stiffener assemblies shall be used at seismic restraints for hanger rods over

6 inches in length. A minimum of two rod stiffener clamps shall be used on any rod

stiffener assembly.

B. Lateral and longitudinal bracing shall be installed between 45 degrees above and

45 degrees below horizontal, inclusive, relative to the horizontal centerline of the pipe.

C. Welded and bolted attachments to the building structural steel shall be in accordance

with the requirements of the AISC Manual of Steel Construction. There shall be no drilling

or burning of holes in the building structural steel without approval of the Construction

Manager.

D. Embedded anchor bolts shall be used instead of concrete inserts for seismic brace

installations in areas below water surface or normally subject to submerging.

E. The Contractor shall install thermal pipe hanger shields on insulated piping at required

locations during restraint installation. Butt joint connections to pipe insulation shall be

made at the time of insulation installation in accordance with the manufacturer's

recommendations.

F. Restraint components in contact with plastic pipe shall be free of burrs and sharp edges.

G. Rollers shall roll freely without binding.

H. Plastic or rubber end caps shall be provided at the exposed ends of all framing channels

that are located up to 7 feet above the floor.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Eccentric Plug Valves for Liquid Service



15110 - 1

SECTION 15110

ECCENTRIC PLUG VALVES FOR LIQUID SERVICE

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies eccentric plug valves.


A. References:

















Reference Title


ASTM A126 Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A276 Stainless and Heat-Resisting Steel Bars and Shapes

ASTM A436 Austenitic Gray Iron Castings


AWWA C504 Rubber Seated Butterfly Valves

B. Proof of Design Tests:

1. The Contractor shall furnish the Construction Manager three certified copies of a

report from an independent testing laboratory certifying successful completion of

proof-of-design testing conducted in accordance with AWWA C504, Section 5.2,

except that where the word "disc" appears in the standard, it is understood to mean

"plug." In lieu of testing the valves at an independent testing laboratory, proof-of-

design testing may be performed at the valve manufacturer's laboratory, but must be

witnessed by a representative of a qualified independent testing laboratory, and all

test reports must be certified by the laboratory representative. Proof-of-design testing

shall have been performed on not less than three 6-inch diameter valves, with all

three test units demonstrating full compliance with the test standards. Failure to




15110 - 2

satisfactorily complete the test shall be deemed sufficient evidence to reject all

valves of the proposed make or manufacturer's model number.

PART 2 PRODUCTS

2.01 MATERIALS

A. Materials of construction shall be as follows:

Component Material

Body Stainless Steel, Type 316

Plug Stainless Steel, ASTM A351, CF8M or ASTM A276, Type 316

Plug facing Stainless Steel, Type 316

Body seats Stainless steel, ASTM A276, Type 304

Packing Solid PTFE

B. Materials specified are considered the minimum acceptable for the purposes of

durability, strength, and resistance to erosion and corrosion. The Contractor may propose

alternative materials for the purpose of providing greater strength or to meet required

stress limitations. However, alternative materials must provide at least the same

qualities as those specified for the purpose.

2.02 MANUFACTURE

A. General:

1. Valves shall be straight-flow nonlubricated resilient plug type suitable for driptight, bi-

directional shutoff at the specified valve design pressure. Port areas for the valve

shall be at least 80 percent of the adjacent full pipe area and shall be capable of

passing solids 75% of pipe size. Valve body seats consisting of nickel for valves 3

inches and larger shall be constructed of a welded-in overlay of not less than 90

percent pure nickel. Upper and lower journal bearings shall be replaceable, sleeve-

type, corrosion resistant, and permanently lubricated. Packing shall be self-adjusting

chevron type replaceable without disassembling the valve.

2. Unless otherwise specified, valves shall, as a minimum, conform to the following

pressure ratings:

Size, inches Design pressure, psig

12 and smaller 225

B. End Connections:

1. Valves 3 inches and smaller shall have threaded ends. Valve flange drilling for valves

larger than 3 inches shall be per ANSI B16.1, Class 125.




15110 - 3

C. Manual Operators:

1. Unless otherwise specified, valves 4 inches and smaller shall be provided with a lever

type manual operator. Valves larger than 4 inches shall be provided with totally

enclosed worm gear operators. Valves installed above 5 ft above finished floor/grade

shall be chain operated. Where specified, manual operators shall have an adjustable

stop. All operator components shall be sized for the valve design pressure in

accordance with AWWA C504, Section 4.5. Operators shall comply with applicable

portions of Section 15184.

2.03 PRODUCT DATA


1. Manufacturer's product data.

2. Proof-of-design test reports specified in paragraph 1.02 Proof of Design Tests.

PART 3 EXECUTION

3.01 INSTALLATION

A. Unless otherwise specified, valves shall be provided with the seat downstream away from

flow. Valves at tank connections shall be installed with seat away from tank. Valves on

pump discharge lines shall be installed with seat adjacent to the pump.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Nonclog Ball Check Valve



15120 - 1

SECTION 15120

NONCLOG BALL CHECK VALVE

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies nonclog ball check valves.

B. Type:

1. The nonclog check valves shall consist of three components: body, cover, and ball--

one moving part. The design of the valve shall keep solids, stringy material, grit, rags,

etc., moving without the need for backflushing. The ball shall clear the waterway

providing "full flow" equal to the nominal size. There shall be no outside levers,

weights, springs, dashpots, or other accessories.

1.02 REFERENCES















or replaced.

Reference Title


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. The Owner and Construction Manager believe the following candidate manufacturers are

capable of producing equipment and/or products that will satisfy the requirements of

this Section. This statement, however, shall not be construed as an endorsement of a

particular manufacturer’s products, nor shall it be construed that named manufacturers’

standard equipment or products will comply with the requirements of this Section.

Candidate manufacturers include Flygt, Golden Anderson, or equal.

Durham AWWTF – FOG Tank Retrofit Project Nonclog Ball Check Valve



15120 - 2

2.02 COMPONENTS

A. Body and Cover:

1. Valve body and cover shall be of gray cast iron or ductile iron. Flange drilling shall be

according to ANSI B16.1, Class 125.

B. Ball:

1. The valve ball shall be hollow steel with an exterior of nitrile rubber. It shall be

resistant to grease, petroleum products, animal and vegetable fats, diluted

concentrations of acids and alkalines (pH 4 to 10), tearing, and abrasion.

C. Seals

1. Seals for FOG, FOG/RCY and FF service shall be FKM or Viton (fluoro-elastomer).

2.03 PRODUCT DATA

A. Manufacturer's product data shall be provided in accordance with Section 01330.

B. Applicable operation and maintenance information specified in Section 01782 shall be

provided in accordance with Section 01330.

PART 3 EXECUTION

3.01 INSTALLATION

A. Installation shall be in accordance with manufacturer's recommendations.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Knife Gate Valve



15136 - 1

SECTION 15136

KNIFE GATE VALVES

GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies knife gate valves.

B. Type:

1. Type A Knife gate valves shall be provided for 12-inch diameter and smaller sizes of

knife gate valves shown unless otherwise specified herein. Type A valves shall be

suitable for 150 psi service and capable of withstanding a back pressure head of at

least 110 psi. Valves shall have rising stems with handwheel operators. All Type A

valves shall be capable of zero leakage shutoff in either flow direction and dead end

isolation service with the downstream pipe flange removed.

1.02 REFERENCES


section as specified and modified. In case of conflict between the requirements of this

section and those of the listed documents, the requirements of this section shall prevail.

Reference Title

ANSI B16.5-81 Pipe Flanges and Flanged Fittings

MSS-SP-81-81 Stainless Steel, Bonnetless, Flanged, Knife Gate Valves (Revised

1986)

PRODUCTS

2.01 MANUFACTURERS

A. The Owner and Construction Manager believe the following candidate manufacturers are

capable of producing equipment and/or products that will satisfy the requirements of

this Section. This statement, however, shall not be construed as an endorsement of a

particular manufacturer’s products, nor shall it be construed that named manufacturers’

standard equipment or products will comply with the requirements of this Section.

Candidate manufacturers include Dezurik, Fabri-Valve, or equal.

2.02 MATERIALS

Component Material

Body Stainless steel, type 304

Wetted interior parts Stainless steel, type 304

Seat rings FKM

Slide Stainless steel, type 304

Stem Stainless steel, type 304

Durham AWWTF – FOG Tank Retrofit Project Knife Gate Valve



15136 - 2

2.03 CONSTRUCTION

A. General:

1. Knife gate valves shall have stainless steel lugged bodies conforming to the general

requirements of MSS-SP-81. Valves shall be provided with 125- or 150-pound

flanges conforming to ANSI B16.5 and the piping systems specified in

Section 15050.

B. Lining and Seating:

1. The interior of the valve body, the contact surfaces of the flanges, and all other

wetted parts shall be lined with type 304 stainless steel. The interior of the body

shall have a machined seating area to provide a smooth, uniform contact with the

knife gate edge. The face of the seating area shall be fitted with a molded,

replaceable FKM ring secured to the valve body interior. The seating ring shall be

designed to allow zero leakage when the valve is closed hand tight at the rated head.

Seating wedges and chest buttons shall be provided to position the knife gate

securely against the seating ring.

C. Packing:

1. The valve shall be sealed against external leakage by a combination of Teflon-

impregnated kevlar rings and a resilient polyurethane ring.

D. Slide:

1. The slide shall be type 304 stainless steel and shall be beveled and machined to

evenly match the seating area in the valve body.

E. Stem and Manual Operators:

1. Valves shall have rising stems with handwheel operators. Valves located above

operator level shall be provided with chain driven operators.

2.04 PRODUCT DATA

A. Manufacturer’s product data shall be provided in accordance with Section 01330.

B. Applicable operation and maintenance information specified in Section 01782 shall be

provided in accordance with Section 01330.

EXECUTION

3.01 GENERAL

A. Valves shall be installed to provide seating in the direction of flow. The Contractor shall

provide temporary blind flanges or other means acceptable to the Owner prior to

pressure testing downstream piping.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Solenoid Valves



15147 - 1

SECTION 15147

SOLENOID VALVES

PART 1 GENERAL

1.01 SCOPE

A. This section covers the furnishing of manually operated or remote activated two position

(open-close) solenoid operated valves.

1. Piping, pipe supports, insulation, and accessories that are not an integral part of the

valves or are not specified herein are covered in other sections.

B. General

1. Section 11000, General Requirements for Equipment:

a. General Requirements for Equipment shall apply to all equipment furnished

under this section. If requirements in this specification differ from those in the

General Requirements for Equipment, the requirements specified herein shall

take precedence.

C. Identification

1. Valves specified herein shall be tagged in accordance with Section 16075, Electrical

Identification.

1.02 SUBMITTALS

A. Complete drawings, details, and specifications covering the valves and their

appurtenances shall be submitted in accordance with Section 01330, Submittal

Procedures.

PART 2 PRODUCTS

2.01 CONSTRUCTION

A. Solenoid valves shall have packless construction without packing box or sliding seal.

B. Solenoid coils for AC service shall be 120 volts, 60 hertz, encapsulated, Class F, for

continuous duty at rated voltage ± 10 percent and 40°C ambient, in a NEMA Type 4X

enclosure, with a conduit knockout.

C. Valves shall be normally closed unless otherwise specified or indicated on the drawings.

Normally open solenoid valves shall close when energized and normally closed solenoid

valves shall open when energized.

D. Valves shall be slow closing-type.




15147 - 2

2.02 VALVES

A. Type VSOL-1

VSOL-1

Non-Potable Water

/ Hot

Type 2-Way, pilot operated

Body/Bonnet

Trim

Seals

Disc

Stem

Bonnet Gasket

Spring

End Connection

Temp. Limitations

Valve Operator

Manufacturers

304 stainless steel

Buna-N or Teflon

Buna-N or Teflon

Manufacturer's standard



Threaded

32 to 104°F

Integral

ASCO "8210 Series"

2.03 LENGTH TOLERANCE

A. Unless otherwise specified, the actual length of valves shall be within± 1/16 inch of the

specified or theoretical length.

2.04 SHOP COATINGS

A. All ferrous metal surfaces of valves and accessories, both interior and exterior, shall be

shop coated for corrosion protection. The valve manufacturer's standard coating will be

acceptable, provided it is functionally equivalent to the specified coating.

Coating Materials

Asphalt Varnish Fed Spec TT-C-494

Coal Tar Epoxy High-build coal tar epoxy; Ameron "Amercoat 78HB Coal Tar

Epoxy", Carboline "Bitumastic 300 M", Tnemec "46H-413 Hi-

Build Tneme-Tar", or Sherwin-Williams "Hi-Mil Sher-Tar Epoxy".

Epoxy Enamel (for liquid service) Ameron "Amerlock 400 High-Solids Epoxy Coating", Carboline

"Carboguard 891", or Tnemec "Series N140 Pota-Pox Plus"

Rust-Preventive Compound As recommended by the manufacturer.

Surfaces To Be Coated

Unfinished Surfaces

Interior Surfaces None

Exterior Surfaces of Valves To Be

Buried, Submerged, or Installed in

Manholes or Valve Vaults

Asphalt varnish or coal tar epoxy.

Exterior Surfaces of All Other Valves Universal primer

Polished or Machined Surfaces Rust-preventive compound

2.05 ACCESSORIES

A. Manual Operators:

1. Valves shall be furnished with manual operators to allow valve operation when

electrical power is off.




15147 - 3

PART 3 EXECUTION

3.01 INSTALLATION

A. Materials furnished under this section shall be installed in accordance with

manufacturer’s recommendations.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Manual Actuators



15184 - 1

SECTION 15184

MANUAL ACTUATORS

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies manual operators for valves and gates, and operator

appurtenances.

1.02 REFERENCES

















Reference Title

AWWA C500 Gate Valves 3 through 48 inch NPS, for Water and Sewage Systems

PART 2 PRODUCTS

2.01 GENERAL

A. Except as specified in valve and gate specification sections, manual operators shall be as

specified herein. Operators shall be mounted on the valve or gate and provided as a unit.

Each valve body or operator shall have cast thereon the word "OPEN," an arrow indicating

the direction to open, and flow direction arrows.

2.02 OPERATORS

A. General:

1. Manual operators shall have operating torques less than 80 foot-pounds. Unless

specified otherwise, each manual operator shall be provided with an operating wheel.

Unless specified otherwise, the direction of rotation of the operator shall be

counterclockwise for opening.




15184 - 2

B. Wrench Nuts:

1. Wrench nuts shall comply with Section 3.15 of AWWA C500. A minimum of two

operating keys, but no less than one key per every ten valves, shall be provided for

operation of the wrench nut operated valves.

C. Chain Wheels:

1. Chain wheels shall be ductile iron. Operating chains shall be galvanized.

2.03 OPERATOR APPURTENANCES

A. Valve Boxes:

1. Valve boxes shall be cast iron and shall have suitable base castings to fit properly

over the bonnets of their respective valves and heavy top sections with stay-put

covers. Covers shall be hot-dip galvanized.

B. Floor Boxes:

1. Floor boxes shall be hot-dip galvanized. Where the operating nut is in the concrete

slab, the floor box shall be bronze bushed. Where the operating nut is below slab, the

opening in the bottom of the box shall be sufficient for passage of the operating key.

C. Adjustable Shaft Valve Boxes:

1. Adjustable shaft valve boxes shall be concrete or cast iron Brooks No. 3RT, Christie

G5, Empire 7-1/2 valve extension box, or equal. Box covers on water lines shall be

impressed with the letter "W." Gas line covers shall be impressed with the letter "G."

2.04 PRODUCT DATA

A. Manufacturer's catalog information and other data confirming conformance to design

and material requirements shall be provided in accordance with Section 01330.

PART 3 EXECUTION

3.01 GENERAL

A. Installation shall be as specified herein. Valve operators shall be located so that they are

readily accessible for operation and maintenance. Valve operators shall be mounted for

unobstructed access, but mounting shall not obstruct walkways. Valve operators shall

not be mounted where shock or vibration will impair their operation. Support systems

shall not be attached to handrails, process piping, or mechanical equipment.

3.02 OPERATORS

A. General:

1. Valves and gates shall be provided with manual operators, unless specified

otherwise. Where possible, manual operators shall be located between 48 inches

and 60 inches above the floor or a permanent work platform.




15184 - 3

B. Wrench Nuts:

1. Wrench nuts shall be provided on buried valves, on valves which are to be operated

through floor boxes, and where specified. Extended wrench nuts shall be provided if

necessary so that the nut will be within 6 inches of the valve box cover.

C. Chain Wheels:

1. Unless otherwise specified, valves with centerlines more than 7 feet, 6 inches above

the specified operating level shall be provided with chain wheels and operating

chains. Chain wheel operated valves shall be provided with a chain guide. Operating

chains shall be looped to extend within 4 feet of the specified operating level below

the valve. For plug-type valves 8 inches and larger, the operator shall be provided

with a hammer blow wheel. Hooks shall be provided for chain storage where the

chain may hang in a walkway.

3.03 OPERATOR APPURTENANCES

A. Valve Boxes:

1. Valve boxes extending to finished surfaces shall be provided for buried valves.

B. Floor Boxes:

1. Floor boxes shall be provided for wrench operation of valves located below concrete

slabs. Each floor box and cover shall be of the depth required for installation in the

slab.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Electric Motorized Actuators



15185 - 1

SECTION 15185

ELECTRIC MOTORIZED ACTUATORS

GENERAL

1.01 SUMMARY

A. Section includes: Electric motor-driven actuators for valves and gates as identified in the

valves and gate schedule.

B. Related sections:

1. The Contract Documents are complementary; what is called for by one is as binding

as if called for by all.

2. It is the Contractor’s responsibility for scheduling and coordinating the Work of

subcontractors, suppliers, and other individuals or entities performing or furnishing

any of Contractor’s Work.

3. The following Sections are related to the Work described in this Section. This list of

Related Sections is provided for convenience only and is not intended to excuse or

otherwise diminish the duty of the Contractor to see that the completed Work

complies accurately with the Contract Documents.

a. Section 15110 – Eccentric Plug Valves for Liquid Service.

1.02 REFERENCES

A. American Water Works Association (AWWA):

1. AWWA C504 - Rubber-Seated Butterfly Valves.

2. AWWA C542 - Electric Motor Actuators for Valves and Slide Gates.

B. FM Global (FM).

C. National Electrical Manufacturers Association (NEMA):

1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS

A. NEMA:

1. Type 4 enclosure in accordance with NEMA 250.

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

3. Type 7 enclosure in accordance with NEMA 250.

1.04 SUBMITTALS

A. Product data:

1. Electrical ratings:

a. Voltage and number of phases.

b. Starting and running current.

c. Voltage levels and source for control and status.

2. Description of integral control interface.




15185 - 2

3. Integral and remote control station components.

4. Environmental ratings, including NEMA enclosure rating and submergence

capabilities.

5. Gear ratios for both manual and motorized actuation.

6. Opening and closing directions.

7. Allowable starts per hour.

8. List of all included options and accessories.

9. Full travel times.

10. Gearbox data including gear ratio, and gearbox efficiency.

11. Affidavit in accordance with AWWA C542.

B. Shop drawings:

1. Wiring diagrams:

a. Include all options and expansion cards furnished with each actuator.

2. Dimensioned drawings of each valve and actuator combination.

3. Dimensioned drawings of each valve gearbox.

4. Electric motor data.

C. Calculations: Submit the following for each valve/gate size and class:

1. Operating torque calculations.

2. Maximum torque calculations for seating and unseating.

3. Maximum operating torque at starting and normal operation.

4. Indicate factor of safety for all torque calculations.

D. Test reports:

1. Factory test report and certificate.

E. Manufacturer's instructions:

1. Include manufacturer's instructions, description of system operation, start-up data

and troubleshooting check lists.

F. Operations and maintenance data:

1. Include manufacturer's literature; cleaning procedures, replacement part lists, wiring

diagrams, and repair data.

2. Include a list of all configurable parameters, and the final values for each.

3. List of recommended spare parts.

4. List of special tools necessary for proper operation and/or maintenance.

5. Exploded view drawings that illustrate all assemblies, sub-assemblies, and

components.

6. Routine test procedures for all electronic and electrical circuits.

7. Troubleshooting chart covering the complete valve and controls/electrical power

systems, showing description of trouble, probable cause, and suggested remedy.

8. Certified factory and field-test results.




15185 - 3


A. Obtain required information from the valve/gate supplier, including but not limited to:

1. Interface to gate or valve.

2. Operating range.

3. Direction of rotation for opening and closing.

4. Maximum and normal torque requirements.

B. All motorized, intelligent actuators shall be the product of a single manufacturer for all

valve and gate applications on this project, regardless of gate or valve type,

manufacturer, or supplier.

1.06 WARRANTY

A. Refer to Contract Documents.

PRODUCTS

2.01 MANUFACTURERS

A. Acceptable Manufacturers for lines 4 inch and larger:

1. Quarter Turn Actuators, Open/Closed or Modulating

a. Beck Group 11 Series

b. No exceptions

2.02 MANUFACTURED UNITS

A. Actuators for valves 4 inch and larger:

1. Provide actuators complete and operable with all components and accessories

required for operation.

2. Power supply:

a. Voltage and phases as indicated on the Valve and Gate Actuator Schedule.

b. Valve or gate motion independent of power supply phase rotation.

3. Size actuator to move gates or valves from full open to closed position within the

time indicated in the Valve and Gate Actuator Schedule:

a. If an operating time is not indicated on the Schedule, size the actuator to move

gates or valves at minimum 12 inches per minute under maximum load.

b. Measure rate of closure for valves at maximum diameter of disc, plug, or ball.

4. Control interface:

a. Local interface, integral to actuator:

1) Selector switches:

a) Local-stop-remote:

(1) Motor actuator operation is prevented with the switch in STOP.

b) Open-close:

(1) Controls the valve when local-stop-remote is in LOCAL.

(2) Spring return to center.




15185 - 4

(3) Configurable between maintained (actuator runs until end of travel,

high torque, or a local-stop-remote is switched to STOP) and

momentary (actuator stops when lever is released).

b. Control inputs:

1) Capable of using 120 VAC or 24 VDC inputs.

2) Controls the valve when local-stop-remote is in REMOTE.

3) Isolated inputs capable of operating from external control voltage source or

internal power supply:

a) Furnish control power supplies within the actuator.

4) Provide the following inputs:

a) OPEN.

b) CLOSE.

c) STOP.

d) OPEN and CLOSE inputs configurable between maintained (actuator runs

until end of travel, high torque, or a STOP input) and momentary (actuator

stops when command is removed).

c. Status outputs:

1) Monitor relay output: Dry contact, normally closed, opens when actuator is

not in REMOTE or in the event of any internal fault or alarm condition.

2) Dry contact outputs configured for the functions indicated on the Drawings.

Provide the following outputs for all actuators:

a) FULLY CLOSED.

b) FULLY OPEN.

c) Local-stop-remote in REMOTE position.

3) All output contacts rated for 5 amps, 120 VAC and 24 VDC.

d. Analog input:

1) Provide a 4-20 milliampere analog input for analog modulating valves when

indicated on the Drawings or schedule.

2) Modulate valve to maintain position based on analog input value.

3) Maximum input impedance 250 ohms.

e. Analog output[s]:

1) Provide an isolated 4-20 milliampere analog outputs when indicated on the

Drawings or schedule:

a) Loop power sourced from the actuator power supply.

b) Capable of driving into a load up to 500 ohms.

c) Output proportional to process value(s) indicated on the Drawings.

d) Valve or gate position.

e) Operating torque.

2.03 FEATURES

A. Time delay on reversal: Incorporate time delay between stopping actuator and starting in

opposite direction to limit excessive current, torque, and heating from instantaneous

reversal.




15185 - 5

2.04 MATERIALS

A. Construct motorized actuators of materials suitable for the environment in which the

valve or gate is to be installed.

2.05 COMPONENTS

A. Motors:

1. Specifically designed for valve actuator service with high starting torque, totally

enclosed non-ventilated construction.

2. Torque ratings equal to or greater than that required for valve seating and dynamic

torques with a minimum of 25 percent factor of safety:

a. Design requirements for rubber-seated AWWA butterfly valves:

1) Design valves and actuators for maximum operating torque, in accordance

with and using safety factors required in AWWA C504 and AWWA C542:

a) Valve actuator torque requirement for open-close service: Not less than

the required valve-seating and dynamic torques under design operating

conditions in accordance with AWWA C504.

b) Valve actuator torque requirement for modulating service: Not less than

twice the required valve dynamic torque under design operating

conditions in accordance with AWWA C504.

b. Design requirements for slide gates, gate valves, knife gate valves, globe valves,

and diaphragm valves:

1) Design valves and actuators for maximum operating torque, in accordance

with and using safety factors required in AWWA C542.

2) Design for the maximum torque and thrust running load over the full cycle.

3) Maximum torque or thrust rating: The actuator stall torque or maximum

thrust output shall not exceed the torque or thrust capability of the valve or

gate, as determined by the valve or gate manufacturer.

3. Capable of being removed and replaced without draining the actuator gear case.

4. Motor bearings shall be amply proportioned of the anti-friction type and permanently

lubricated.

5. Rated for operating under the following conditions without exceeding temperature

limits with ambient temperature of 40 degrees Celsius:

a. Continuous operation for 30 minutes or twice the open-to-close operating time

(whichever is greater) at normal operating torque or 33 percent of maximum

torque (whichever is greater).

b. 60 starts per hour for open/close service or 1,200 starts per hour for modulating

service.

6. Provide the following motor protection features:

a. Jammed valve (no valve motion detected through a time delay).

b. High motor temperature (sensed by embedded thermostats).

c. High torque.

d. Single phasing protection for 3-phase motors.

B. Enclosures:

1. Actuator housing ratings as indicated in the Valve and Gate Actuator Schedule.




15185 - 6

2. Stainless steel external fasteners.

3. Provide seals for each of the following areas:

a. Between the terminal compartment and the internal electrical elements

b. Between the mechanical and electrical portions to protect from the ingress of oil,

and to protect the mechanical components of oil from dust and moisture when

the electrical terminal is open.

4. Provide the following minimum enclosure ratings:

a. NEMA Type 4X for general applications.

C. Position sensing:

1. Integral with valve actuator.

2. Gearing: Intermittent type; bronze or stainless steel; grease lubricated; totally

enclosed.

3. Contacts: Heavy duty and silver-plated with wiping action or encoder wheel.

4. Remote indication contacts: As indicated on the Drawings.

5. Switches: Adjustable; allowing for trip points from fully open to closed positions of

valve travel; not subject to breakage or slippage due to over travel; permits visible

verification of switch position without disassembly.

6. Capable of retaining position and monitoring valve or gate motion when valve is

manually actuated and when main power is not present.

7. Valve range and position switch outputs field adjustable.

D. Torque sensing:

1. Capable of interrupting control circuit in both opening and closing when valve torque

overload occurs.

2. Silver-plated contacts.

3. Graduated dials for both open and close directions of travel, each independently

adjustable or 0-100 LTD display.

4. Positive means to limit adjustability to avoid exceeding actuator output torque

capability with solid-state sensor embedded within the torque transducer.

5. Permits visible verification of switch position without disassembly.

6. Torque shutdown setting: 40 percent to 100 percent rated torque:

7. Adjustable in 1 percent increments.

8. Capable of interrupting control circuit during both opening and closing and when

valve torque overload occurs.

9. Independent of variations in frequency, voltage, or temperature.

10. Provide a temporary inhibit of the torque sensing system during unseating or during

starting in mid-travel against high inertia loads.

E. Manual actuators:

1. Hand wheel for manual operation:

a. Maximum 80 pound pull on rim when operating gate or valve under maximum

load.




15185 - 7

b. Provide pull chain when motorized actuator is located more than 6 feet above

floor surface.

1) Chain shall be of sufficient length to reach approximately 4 feet above the

operating level.

2) Where the chain obstructs an aisle or walkway, provide holdback or other

means to ensure chain does not create a nuisance or hazard to operating

personnel.

2. Declutch lever: With padlock , capable of mechanically disengaging motor and

related gearing and freeing hand wheel for manual operation.

F. Gearing: Hardened alloy steel spur or helical gears and self-locking, alloy bronze worm

gear set:

1. Accurately cut to assure minimum backlash.

G. Bearings:

1. Anti-friction bearing with caged balls or rollers throughout.

2. Sealed-for-life type thrust bearings housed in a separate thrust base.

H. Drive bushing:

1. Easily detachable for machining to suit the valve stem or gearbox input shaft.

2. Positioned in a detachable base of the actuator.

I. Lubrication:

1. Grease Filled.

2. Actuators requiring special or exotic lubricants are not acceptable.

3. Provide seals for all shafts.

2.06 ACCESSORIES

A. Setting tool:

1. If required for setting or configuring the actuator, provide a hand-held setting tool.

a. Furnish 1 setting tool for every 6 actuators.

b. Capable of communicating with PC-based configuration software, and

transferring the following in either direction between the computer and

programmer and setting tool, and between the setting tool and actuator.

c. Actuator configurations:

1) Capable or storing up to ten different configurations.

d. Diagnostic data.

1) Capable of storing 4 complete sets of diagnostic data.


A. Factory test:

1. Test each actuator in the factory, and submit an individual test certificate for each

actuator.

2. Perform a high potential test and record the following information:

a. Test voltage.




15185 - 8

3. Simulate a maximum and typical valve loads and record the following information:

a. Current and power factor at maximum and set torque values.

b. Torque as measured by the actuator.

c. Actuator output speed or operating time.

4. Performance testing: Conduct performance test for each actuator simulating valve

operating torque from full-open to full-close and from full-close to full-open. The

following information shall be recorded during each performance test:

a. Torque at maximum torque setting.

b. Current at maximum torque setting.

c. Test voltage and frequency.

d. Actuator output speed and operating time for full-open to full-close.

e. Amperage draw on motors at breakaway and under normal operation.

EXECUTION

3.01 INSTALLATION

A. Install actuators in accordance with manufacturer's instructions.

3.02 MOTORIZED ACTUATOR SCHEDULE

A. Provide all actuators required by the Drawings. Major process actuators are listed in the

Valve and Gate Actuator Schedule. The schedule does not include all number and types

of actuators required for the Project.

B. Abbreviations relating to type:

1. BFV = Butterfly Valve.

2. BV = Ball Valve.

3. PV = Plug Valve.

4. SG = Slide Gate.

C. Abbreviations relating to actuator type:

1. O/C = Open and Close Service.

2. MOD = Modulating Service.

D. Abbreviations relating to controls:

1. MB = Modbus RTU (RS-485).

2. NET = Manufacturer’s proprietary network.

3. A = Analog (4-20 mA) control, modulating duty.

4. D = Discrete control, modulating duty.

5. D-O/C = Discrete Open/Close.




15185 - 9

3.03 MANUFACTURER’S SERVICES

A. Provide a factory-trained manufacturer’s representative at the Site for the following

activities. Specified durations do not include travel time to or from the Site.

1. Procedures: Section 01640

a. Submit Equipment Supplier’s Certificate of Installation, Section 01756 SUP-1

2. Training: Provide the following training sessions: One, 2-hour training session

VALVE AND GATE ACTUATOR SCHEDULE

Item Reference DWG Type Size Actuator Type NEMA

Rating Voltage Notes Open Time Controls

715FV6411

M

M302

I009A

PV 6” O/C 4/4X 480/3/60 D-O/C

715FV6412

M301

M302

I009A

PV 6” O/C 4/4X 480/3/60 D-O/C

715FV6413

M101

M302

I009A

PV 6” O/C 4/4X 480/3/60 D-O/C

715FV6414

M101

M302

M303

I008A

PV 6” O/C 4/4X 480/3/60 D-O/C

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Process Piping and Equipment Insulation



15250 - 1

SECTION 15250

PROCESS PIPING AND EQUIPMENT INSULATION

PART 1 GENERAL

1.01 DESCRIPTION

A. Scope:

1. This section specifies insulation for exposed, indoor and outdoor piping, tanks and

equipment and appurtenant surfaces.


A. Section 15050 – Piping Systems

B. Section 15096 – Pipe Hangers and Supports

C. Section 15097 – Seismic Restraints for Piping

1.03 REFERENCES















or replaced.

Reference Title

ASTM B209 Aluminum and Aluminum-Alloy Sheet and Plate

ASTM C533 Calcium Silicate Block and Pipe Thermal Insulation

ASTM C534 Preformed Flexible Elastomeric Cellular Thermal Insulation in

Sheet and Tubular Form

ASTM C552 Cellular Glass Thermal Insulation

ASTM E96 Water Vapor Transmission of Materials

FEDSPEC L-P-535E Plastic Sheet (Sheeting) “Plastic Strip” Poly (Vinyl Chloride) and

Poly (Vinyl Chloride-Vinyl Acetate), Rigid

ASTM C547 Mineral Fiber Pipe Insulation




15250 - 2

1.04 DEFINITIONS

A. Terminology used in this Section conforms to the following definitions:

B. Low-temperature range: operating temperature range of -100 to +100 degrees F.

C. Medium-temperature range: operating temperature range of 100 to 800 degrees F.

D. Jacket: protective outer layer placed over insulation on straight runs of pipe

E. Cover: protective outer layer placed over insulation on valves, strainers, expansion joints,

flanges, pipe fittings, couplings, and equipment.

F. Exposed: All area exposures other than buried, submerged, or encased/embedded.


A. Sequencing: After installation of insulation for pipe and equipment is complete, provide

identification as described in Section 15060.

1.06 SUBMITTALS

A. Procedures: Section 01330

B. Action Submittals:

1. This section to be marked-up and submitted include the following. Use check-marks

( ) to denote full compliance with a paragraph as a whole. Underline and denote








2. Manufacturer’s descriptive literature, including insulation and jacket thickness, heat

transfer coefficient, and methods of installation.

3. Certification of jacket ratings for water vapor transmission, puncture and stiffness as

specified.

C. Informational Submittals:

1. Samples of each insulation material type and thickness along with typical jackets and

covers for pipe, fittings, valves and appurtenances. Provide a full diameter segment

for each insulation sample, 6 inches in length.

D. Closeout Submittals:

1. Warranty Documentation




15250 - 3

1.7 DELIVERY, STORAGE, AND HANDLING

A. Procedures: Section 01600

B. Deliver insulation, jackets and covering to site using methods which do not damage the

materials.

C. Deliver insulation materials to site clearly identified as to type and temperature rating.

D. Store insulation materials on site as recommended by the manufacturer to prevent

damage or and weathering.

E. Replace damaged or weathered insulation materials with new materials.

PART 2 PRODUCTS

2.01 GENERAL

A. Outdoor piping insulation shall be tubular type or the flexible blanket type. Insulation for

outdoor valves, strainers, fittings, expansion joints, flanges and other connections shall

be segmented sections, molded, or blanket type coverings of the specified type and

thickness of pipe insulation, or the flexible blanket type. Tank and equipment insulation

shall be flexible blanket type.

2.02 MANUFACTURERS

A. Manufacturers: Candidate manufacturers and models are listed below. The

manufacturer’s standard product may require modification to conform to specified

requirements.

B. Fiberglass

1. Johns Manville, Micro-Lok HP

2. Owens Corning, FIBERGLAS

3. Approved Equal

C. Fiberglass Flexible Blanket

1. Amatex, Amamat

2. Lewco, E Glass

3. Approved Equal

D. Mineral Wool Flexible Blanket

1. Johns Manville, Min-Wool 1200

2. Roxul, Enerwrap MA 960

3. Approved Equal




15250 - 4

2.03 INSULATION

A. General:

1. Exposed piping insulation shall be fiberglass type.

2. Tanks and equipment shall be insulated with flexible blanket type.

B. General:

1. Provide materials that are new and undamaged.

2. Match specified pipe insulation and jacket/cover material for insulation on valves,

strainers, fittings, expansion joints, flanges, and other pipe couplings. Furnish

flexible blanket insulation and soft covers if insulation on valves, strainers, fittings,

expansion joints, flanges, and other pipe couplings is not available in the same

materials as the specified pipe insulation and jacket/cover.

3. Provide rigid insulation and shields at pipe supports for insulated pipe. Match

specified jacket/cover material for pipe shields at pipe supports.

4. Provide insulating and sealing materials, including cements, coverings, etc., that do

not contain asbestos, mercury, or lead.

5. When covering stainless steel pipe, pipeline appurtenances, or equipment, use

insulation that complies with ASTM C795 and has less than 600 mg/liter of

leachable chlorides, and greater than 20 mg/liter of sodium silicate for each mg/liter

of chloride.

6. Flame spread classification for insulation materials is not to exceed 25 when tested

in accordance with ASTM E84.

7. Use fibrous loose fill insulation for joint filler around insulated expansion joints.

C. Fiberglass Type:

1. Fiberglass type insulation shall conform to the requirements of ASTM C547, Type I,

Grade A.

D. Flexible Blanket Type:

1. Fiberglass Flexible Blanket: Flexible fiberglass blanket insulation designed for

continuous 1200 degree F service. The blanket shall be a custom sewn, flexible,

reusable jacket, custom designed to closely fit the piping or the equipment housing.

Blanket shall be custom fitted to not restrict access to any instrumentation or

equipment. Insulation shall not compact or shake down in vibrating service. 8.0

pounds per cubic foot density, minimum. Long fiber, random orientation, needled.

2. Mineral Wool Flexible Blanket: Flexible mineral wool blanket insulation designed for

continuous 1200 degree F service.

E. Aluminum Insulation Jackets/Covers

1. Aluminum jackets and covers constructed of smooth finish aluminum sheet

conforming to ASTM B209, alloy 3003, or 3105 temper H14, with integral vapor

barrier.




15250 - 5

2. Pipe Insulation Jacket thickness per ASTM C1729, as follows.

Outer Insulation

Diameter (inches)

Aluminum jacket thickness, rigid

insulation (inch)

Aluminum jacket thickness,

flexible and semi-rigid insulation

(inch)

≤ 8 0.016 0.016

8 thru 11 0.016 0.020

11 thru 24 0.016 0.024

3. Furnish 0.030 inch, minimum thickness, for aluminum insulation covers at valves,

strainers, fittings, expansion joints, flanges, and other pipe couplings.

4. Aluminum or stainless steel sheet metal screws.

5. Jackets secured with 0.020 inch thick by ¾ inch wide Type 304 stainless steel

expansion bands.

6. Flashing includes aluminum caps, sealant and reinforcing.

7. Provide aluminum caps, 20 gauge. Cut to completely cover the insulation.

8. Provide sealants as recommended by the insulation manufacturer.

9. Provide wire mesh reinforcement or nylon fabric reinforcement in sealant at jacket

and cover joints. Reinforcement material as recommended by the insulation

manufacturer.

F. Laminated Jackets:

1. Laminated jackets shall consist of aluminum and white kraft paper. Jackets shall

have a perm rating for water vapor transmission of not more than 0.02 in accordance

with procedure A of ASTM E96.

G. PVC Insulation Jackets and Covers

1. One piece PVC covers and jackets. 20 mil thickness, minimum.

2. Pre-molded polyvinylchloride conforming to FEDSPEC L-P-535E, Composition A, Type

II, Grade E4 or GU.

H. Non-combustible Fabric Cover

1. Custom fit reusable covers. Sewn or stapled covers encapsulating insulation with

stainless steel staples/hog rings. Close fit to the piping, pipeline appurtenance, or

equipment housing.

2. Fabricated from 32 ounce TFE-coated or silicone coated fiberglass cloth with

concealed/interior stitching, staples or hog rings (not exposed). For flexible blanket

insulation installed for High-Temperature and Very High-Temperature Range

applications, eliminate non-combustible fabric material on hot face of covers and

provide stainless steel wire mesh on hot face of covers.

3. Fabric rated for continuous exposure to the temperature range of the insulation (Low

or Medium Temperature Range).

4. Secured in place with stainless steel lacing hooks, lock washers, and lacing wire.

5. Stitched or quilted to prevent consolidation, shifting, or settlement of insulation when

subjected to vibration.




15250 - 6

I. Flashing

1. Flashing shall include aluminum caps, sealant and reinforcing. Aluminum caps shall

be 20 gage thick and shall be cut to completely cover the insulation. Sealants shall

be as recommended by the insulation manufacturer.

2. Reinforcement in flashing heated up to 370 degrees F shall be nylon fabric.

Reinforcement in flashing for hotter surfaces shall be wire mesh or as recommended

by the insulation manufacturer.

PART 3 EXECUTION

3.01 PREPARATION

A. Apply insulation over clean, dry surfaces.

B. Ensure insulation is dry before and during application.

C. Do not apply protective pipe coatings to outside surface of insulation jackets or covers.

D. Do not paint PVC, aluminum, or fabric covers.

E. Do not install insulation or jackets/covers before piping and equipment has been tested

and approved. Thermal shields at pipe hangers and supports may be installed prior to

testing.

F. Provide thermal pipe hanger shields at pipe supports and bracing as specified on the

Drawings, Details, Section 15096 and Section 15097.

3.02 INSTALLATION

A. General

1. Where double layer insulation is provided to achieve the specified insulation

thickness, install with staggered section joints.

2. Supply insulated thermal pipe hanger shields and install during pipe support

installation. Where insulated thermal pipe hanger shields are used, apply the

following to all butt joints:

a. Apply a wet coat of vapor barrier lap cement on all butt joints and seal the joints

with a minimum 3 inch wide vapor barrier tape or band.

B. Protect insulation and jackets from crushing, denting, and similar damage during

construction. Do not penetrate or otherwise damage vapor barriers. Remove any

insulation, jacket, and vapor barriers damaged during construction and install new

material.

C. Provide flashing at joints between insulation jackets, between insulation jackets and

insulation covers, and at endcaps. Provide flashing around flange sets, pipe

couplings/connections, and joint fittings. Allow adequate clearance between insulation

rings, jackets and the joint connection for the removal and reinstallation of hardware

during inspection and maintenance activities.




15250 - 7

D. Piping Insulation

1. Install uninterrupted (continuous) insulation as indicated for the specified Insulation

Service Conditions (Condensation Control, Energy Conservation, Personnel

Protection, or Freeze Protection). Insulate over pipe and all in-line devices such as

valves, fittings, flanges, couplings, strainers and other piping appurtenances. Butt

insulation firmly together and provide jacket laps and joint strips with lap adhesive.

Install jackets with their seams located on the underside of pipe.

a. PVC covers specified in paragraph 2.03 H Polyvinylchloride (PVC) Covers shall not

be used with medium- or high-temperature class insulation. Removable flexible

blanket-type insulation need not be jacketed.

2. Covers overlap the adjoining pipe insulation and jackets.

3. Install covers with their seams located on the underside of valves, fittings, flanges,

couplings, strainers and other piping appurtenances.

4. Fittings, Connections, Flanges and Valves: Fitting, connection, flange and valve

insulation shall be provided with covers specified in paragraph 2.04. Insulation shall

be secured in place with 20-gage wire and a coat of insulating cement. Covers shall

overlap the adjoining pipe insulation and jackets. Covers shall be provided with their

seams located on the underside of fittings and valves.

5. Insulation for Outdoor Piping

a. Pipe: Rigid insulation shall be provided with aluminum jackets specified in

paragraph 2.04 G Aluminum Jackets. Flexible blanket-type insulation shall be

designed for outdoor, weather-exposed service.

b. Fittings, Connections, Flanges and Valves: Rigid insulation shall be provided with

rigid aluminum covers specified in paragraph 2.04 G Aluminum Covers. Flexible

blanket type insulation shall be designed for outdoor, weather-exposed service.

c. Where insulated pipe emerges from soil, concrete or asphalt terminate insulation

for exposed pipe at the interface with insulation for buried pipe. If buried pipe is

not insulated, extend insulation to within an inch above the finished surface. Do

not push insulation into contact with soil, finished concrete, or asphalt surface.

E. Tank and Equipment Insulation

1. Unless otherwise specified in this Section, fit insulation to the contours of equipment

and secure it with 1/2 by 0.015 inch stainless steel bands. Weld pins or stick clips

with washers may be used for flat surfaces and spaced a maximum 18 inches apart.

Stagger joints and fill voids with insulating cement. Unless otherwise specified,

insulation shall be provided with laminated jackets specified in paragraph 2.04

H Laminated Jackets.

a. Unless specifically specified to be uninsulated, equipment connected to insulated

piping shall be insulated.

2. Overlap ends of blanket segments to prevent gaps and voids when the piping and

equipment are heated.

3. Secure blankets snugly under nuts and bolt heads to assure complete coverage

during operation and to prevent vibration-induced gaps or voids.

4. Secure blankets in strict accordance with the manufacturer's instructions.

5. Outdoor Equipment: Insulation shall be provided with a coat of weatherproof mastic

and a layer of open-weave glass cloth embedded into a wet tack coat. Seams shall

overlap at least 2 inches. A finish coat of weatherproof mastic shall be provided. The

total coating thickness shall be a minimum of 1/8 inch.




15250 - 8

6. Insulation shall be provided with a layer of open-weave glass cloth embedded into a

wet coat of fire-retardant adhesive. Seams shall overlap at least 2 inches. A finish

coat of fire-retardant adhesive shall be provided.

7. Blanket-type insulation shall be secured with stainless steel wire lacing and hooks.

Ends of blanket segments shall overlap to prevent gaps and voids when the piping

and equipment is heated. Blankets shall be snugly secured under nuts and bolt

heads to assure complete coverage during operation and to prevent vibration-

induced gaps or voids. Blankets shall be secured in strict accordance with the

manufacturer's instructions.

F. Flashing

1. Provide flashing at jacket penetrations and terminations. Provide clearance for

flashing between insulation system and piping supports.

2. A heavy tack coat of sealant shall be troweled over the insulation, extending over the

jacket edge 1 inch and over the pipe or protrusion 2 inches. Reinforcement shall be

stretched over the tack coat after clipping to fit over pipe and jacket. Clipped

reinforcing shall be strapped with a continuous band of reinforcing to prevent curling.

Sealant shall then be troweled over the reinforcement to a minimum thickness of

1/8 inch.

3. Form aluminum caps to fit over the adjacent jacketing and to completely cover

coated insulation. Hold cap in place with a jacket strap.

3.03 INSULATION THICKNESS SCHEDULE

A. The insulation dimensional tolerances shall comply with the specified standards.

Equipment insulation shall match thickness of attached piping. The minimum insulation

thicknesses, exclusive of jacket, shall be as follows:

Piping

Servicea

Insulation

Service

Location Fluid Temperature

Range, Degrees F

Insulation Thickness in Inches for Nominal Pipe Sizes

Runouts up

to 2 inchesb 1 inch and

less

1.25 to 2

inches

2.50 to 4

inches

5 and

6

inches

Process

• FOG Energy

Conservation

Outdoors 80-150 1.5 1.5 1.5 1.5 1.5

• FOG REC Energy

Conservation

Outdoors 80-150 1.5 1.5 1.5 1.5 1.5

• FF Energy

Conservation

Indoors/Out

doors

80-150 1.5 1.5 1.5 - -

Service

Water

• NPW/H Energy

Conservation

Indoors/

Outdoors

70-150 1.0 1.0 1.0 - -

• NPW

(SEAL

WATER)

Freeze

Protection

Outdoors 40-70 1.0 1.0 1.0 - -

• HPHW Energy

Conservation

Indoors/Out

doors

70-150 1.0 1.0 1.0 - -

Equipment




15250 - 9

Piping

Servicea

Insulation

Service

Location Fluid Temperature

Range, Degrees F

Insulation Thickness in Inches for Nominal Pipe Sizes

Runouts up

to 2 inchesb 1 inch and

less

1.25 to 2

inches

2.50 to 4

inches

5 and

6

inches

• FOG

Tanks

Energy

Conservation

Outdoors 80-150 4.0 inch insulation on all tank surfaces, nozzles and

connections. Insulate legs down to 3 ft above tank

foundation.

aSee specification Section 15050 and Contract Drawing G004.

bRunouts to individual terminal units (not exceeding 12 feet in length).

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Common Work Results for Electrical



16050 - 1

SECTION 16050

COMMON WORK RESULTS FOR ELECTRICAL

GENERAL

1.01 SUMMARY

A. Section includes:

1. General requirements applicable to all Electrical Work.

2. General requirements for electrical submittals.




2. It is the Contractor’s responsibility to schedule and coordinate the Work of



3. The following sections are related to the Work described in this Section. This list of

related sections is provided for convenience only and is not intended to excuse or



a. Document 00700, Standard General Conditions of the Construction Contract

b. Section 00100, Instructions to Bidders

c. Section 01140, Work Restrictions and Sequencing

d. Section 01292, Schedule of Values

e. Section 01324, CPM Construction Schedule

f. Section 01329, Safety Plan

g. Section 01330, Submittal Procedures

h. Section 01450, Quality Control

i. Section 01500, Temporary Facilities and Controls

j. Section 01610, Project Design Criteria

k.j. Section 01756, Testing, Training and Facility Startup

l.k. Section 01770, Closeout Procedures

m.l. Section 01782, Operation and Maintenance Data

n.m.Division 16

C. Interfaces to equipment, instruments, and other components:

1. The Drawings, Specifications, and overall design are based on preliminary

information furnished by various equipment manufacturers which identify a minimum

scope of supply from the manufacturers. This information pertains to, but is not

limited to, instruments, control devices, electrical equipment, packaged mechanical

systems, and control equipment provided with mechanical systems.




16050 - 2

2. Provide all material and labor needed to install the actual equipment furnished, and

include all costs to add any additional conduit, wiring, terminals, or other electrical

hardware to the Work, which may be necessary to make a complete, functional

installation based on the actual equipment furnished:

a. Make all changes necessary to meet the manufacturer’s wiring requirements.

3. Submit all such changes and additions to the Engineer for acceptance as specified in

Document 00700, Standard General Conditions of the Construction Contract.

4. Review the complete set of Drawings and Specifications in order to ensure that all

items related to the electrical power and control systems are completely accounted

for. Include any such items that appear on the Drawings or in the Specifications from

another discipline in the scope of Work:

a. If a conflict between Drawings and Specifications is discovered, refer conflict to

the Engineer as soon as possible for resolution.

5. Loop drawings:

a. Provide all electrical information required in the preparation of loop drawings

including, but not limited to:

1) Conduit numbers and associated signal(s) contained within each conduit.

2) Wire numbers.

3) Equipment terminal numbers.

4) Junction boxes and signal(s) contained within each junction box.

5) Equipment power sources, and associated circuit numbers.

6) As-built drawings detailing wiring.

D. All electrical equipment and systems for the entire Project must comply with the

requirements of the Electrical Specifications, whether referenced in the individual

Equipment Specifications or not:

1. The requirements of the Electrical Specifications apply to all Electrical Work specified

in other sections, including HVAC controls, packaged mechanical systems, LCPs,

VCPs, etc.

2. Inform all vendors supplying electrical equipment or systems of the requirements of

the Electrical Specifications.

3. The Owner is not responsible for any additional costs due to the failure of the

Contractor to notify all subcontractors and suppliers of the Electrical Specifications

requirements.

E. Special subcontractor requirements:

1. As specified elsewhere in this Section, provide the Work specified in the Electrical

Specifications by a qualified electrical subcontractor.

F. Contract Documents:

1. General:

a. The Drawings and Specifications are complementary and are to be used together

in order to fully describe the Work.

2. Specifications:

a. The General and Supplementary Conditions of the Contract Documents govern

the Work.

b. These requirements are in addition to all General Requirements.




16050 - 3

3. Contract Drawings:

a. The Electrical Drawings show desired locations, arrangements, and components

of the Electrical Work in a diagrammatic manner.

b. Locations of equipment, control devices, instruments, boxes, panels, etc. are

approximate only; exercise professional judgment in executing the Work to

ensure the best possible installation:

1) The equipment locations and dimensions indicated on the Drawings are

approximate. Use the shop drawings to determine the proper layout,

foundation, and pad requirements, etc. for final installation. Coordinate with

all subcontractors to ensure that all electrical equipment is compatible with

other equipment and space requirements. Make changes required to

accommodate differences in equipment dimensions.

2) The Contractor has the freedom to select any of the named manufacturers as

identified in the individual specification sections; however, the Engineer has

designed the spatial equipment layout based upon a single manufacturer and

has not confirmed that every named manufacturer’s equipment fits in the

allotted space. It is the Contractor’s responsibility to ensure that the

equipment being furnished fits within the defined space.

c. Installation details:

1) The Contract Drawings include typical installation details the Contractor is to

use to complete the Electrical Work. For cases where a typical detail does not

apply, develop installation details that may be necessary for completing the

Work, and submit these details for review by the Engineer.

2) Not all typical installation details are referenced within the Drawing set. Apply

and use typical details where appropriate.

d. Schematic diagrams:

1) All controls are shown de-energized.

2) Schematic diagrams show control function only. Incorporate other necessary

functions for proper operation and protection of the system.

3) Add slave relays, where required, to provide all necessary contacts for the

control system or where needed to function as interposing relays for control

voltage coordination, equipment coordination, or control system voltage drop

considerations.

4) Mount all devices shown on motor controller schematic diagrams in the

controller compartment enclosure, unless otherwise noted or indicated.

5) Schematic diagrams are to be used in conjunction with the descriptive

operating sequences in the Contract Documents. Combine all information

and furnish a coordinated and fully functional control system.

G. Alternates/Alternatives:

1. Coordinate with Document 00700 for substitute item provisions.

H. Changes and change orders:

1. As specified in Document 00700.




16050 - 4

1.02 REFERENCES

A. Code compliance:

1. As specified in Section 01410.

2. The publications are referred to in the text by the basic designation only. The latest

edition accepted by the Authority Having Jurisdiction of referenced publications in

effect at the time of the bid governs.

3. The standards listed are hereby incorporated into this Section.

a. American National Standards Institute (ANSI).

b. American Society of Civil Engineers (ASCE):

1) ASCE 7 - Minimum Design Loads for Buildings and Other Structures.

c. ASTM International (ASTM).

d. Illuminating Engineering Society (IES). Institute of Electrical and Electronics

Engineers (IEEE).

e. Insulated Cable Engineers Association (ICEA).

f. International Code Council (ICC).

1) International Code Council Evaluation Service (ICC-ES).

a) AC 156 – Acceptance Criteria for Seismic Certification by Shake Table

Testing of Non-Structural Components (ICC-ES AC 156).

g. International Society of Automation (ISA).

h. National Electrical Manufacturers Association (NEMA):

1) 250 - Enclosures for Electrical Equipment (1000 V Maximum).

i. National Fire Protection Association (NFPA):

1) 70 - National Electric Code (NEC).

j. National Institute of Standards and Technology (NIST).

k. Underwriters' Laboratories, Inc. (UL).

B. Compliance with laws and regulations:

1. As specified in Document 00700.

1.03 DEFINITIONS

A. Definitions of terms and other electrical and instrumentation considerations as set forth

by:

1. IEEE.

2. NETA.

3. IES.

4. ISA.

5. NEC.

6. NEMA.

7. NFPA.

8. NIST.




16050 - 5

B. Specific definitions:

1. FAT: Factory acceptance test.

2. ICSC: Instrumentation and controls subcontractor.

3. LCP: Local control panel: Operator interface panel that may contain an HMI, pilot type

control devices, operator interface devices, control relays, etc. and does not contain

a PLC or RIO.

4. LCS: Local control station: Operator interface panel that may contain pilot type

control devices, operator interface devices, etc.

5. PCM: Process control module: An enclosure containing any of the following devices:

PLC, RTU, or RIO.

6. PCIS: Process control and instrumentation system.

7. RTU: Remote telemetry unit: A controller typically consisting of a PLC, and a means

for remote communications. The remote communications devices typically are radios,

modems, etc.

8. Space: That portion of the switchgear, motor control center, panel-board, switchboard

or control panel that does not physically contain a device but is capable of accepting

a device with no modifications to the equipment, i.e., provide all standoffs, bus, and

hardware, as part of the space.

9. Spare: That portion of the switchgear, motor control center, panel-board, switchboard

or control panel that physically contains a device with no load connections to be

made.

10. System supplier: Refer to Quality Assurance in this Section.

11. VCP: Vendor control panel: Control panels that are furnished with particular

equipment by a vendor other than the ICSC. These panels may contain PLCs, RIO,

OIT, HMI, etc.

12. Unequipped space: That portion of the switchgear, motor control center, panel-board,

switchboard or control panel that does not physically contain a device, standoff, bus,

hardware, or other equipment.

1.04 SYSTEM DESCRIPTION

A. General requirements:

1. The Work includes everything necessary for and incidental to executing and

completing the Electrical Work indicated on the Drawings and specified in the

Specifications and reasonably inferable there from:

a. The Electrical Drawings are schematic in nature; use the Structural, Architectural,

Mechanical, and Civil Drawings for all dimensions and scaling purposes.

2. It is the intent of these Specifications that the entire electrical power,

instrumentation, and control system be complete and operable. Provide all necessary

material and labor for the complete system from source of power to final utilization

equipment, including all connections, testing, calibration of equipment furnished by

others as well as equipment furnished by the Contractor, whether or not specifically

mentioned but which are necessary for successful operation.

3. Provide all Electrical Work, including conduit, field wiring, and connections by the

electrical subcontractor under the provisions of the Electrical Specifications for all

aspects of the Work, including heating, ventilating, and air conditioning.




16050 - 6

4. Coordinate all aspects of the Work with the electrical subcontractor and other

subcontractors before bidding in order to ensure that all costs associated with a

complete installation are included. The Owner is not responsible for any change

orders due to lack of coordination of the Work between the Contractor, the electrical

subcontractor, the other subcontractors or suppliers.

5. Demolition:

a. Where demolition is specified or indicated on the Drawings, disconnect all

associated electrical equipment and render the equipment safe.

b. Remove and dispose of all conduit, wire, electrical equipment, controls, etc.

associated with the items and/or areas to be demolished as indicated on the

Drawings unless otherwise indicated.

c. Salvage electrical equipment as indicated on the Drawings.

d. For each piece of equipment to be removed, remove all ancillary components

(e.g. instruments, solenoid valves, disconnect switches, etc.).

e. Conduit:

1) Where conduit removal, other than associated with equipment to be

removed, is indicated on the Drawings:

a) Remove exposed conduit to the point of encasement or burial.

b) Cut conduit flush and plug or cap encased or buried conduit.

2) Where conduits are to remain in place and removal is not indicated on the

Drawings:

a) Cap conduit open ends.

b) Re-label empty conduits as spare.

f. Remove all wire back to the source for all conduits to be removed or abandoned

in place.

g. Provide new nameplates for modified electrical distribution equipment, motor

control centers etc. to identify equipment and circuits that are no longer used as spares.

h. Provide new typewritten schedules for all modified panel-boards.

i. Provide KO seals in all penetrations in enclosures and equipment that are made

available by the removal of conduits or raceways.

j. Seal all penetrations in walls and floors that are made available by the removal of

conduits or raceways. Grout fill all penetrations in concrete.

6. Portions of this Project involve installation in existing facilities and interfaces to

existing circuits, power systems, controls, and equipment:

a. Perform and document comprehensive and detailed field investigations of

existing conditions (circuits, power systems, controls, equipment, etc.) before

starting any Work. Determine all information necessary to document, interface

with, modify, upgrade, or replace existing circuits, power systems, controls, and

equipment.

b. Provide and document interface with, modifications to, upgrades, or replacement

of existing circuits, power systems, controls, and equipment.

7. Do not penetrate existing enclosures, control panels, or equipment without the Owner

present to observe the installation. The Owner shall observe the Contractor while

these penetrations are created.




16050 - 7

8. Provide all trenching, forming, rebar, concrete, back filling, hard surface removal and

replacement, for all items associated with the Electrical Work and installation:

a. As specified in the Contract Documents.

9. Defective work:

a. As specified in Document 00700 Standard General Conditions of the

Construction Contract.

B. Operating facility:

1. As specified in Section 01140, Work Restrictions and Sequencing.

2. The Forest Grove AWTF is an operating facility. Portions of this facility must remain

fully functional throughout the entire construction period. In consideration of this

requirement, comply with the following guidelines:

a. All outages must be of minimal duration and fully coordinated and agreed to by

the Owner. Adjust the construction schedule to meet the requirements of the

Owner. All changes in schedule and any needs to reschedule are included in the

Work.

b. As weather and water demand conditions dictate, re-adjust the construction

schedule to meet the demands placed upon Owner by its users.

c. Coordinate the construction and power renovation, bear all costs, so that all

existing facilities can continue operation throughout construction.

3. According to individual circumstances and in compliance with the Drawings, extend

or replace conduit and cable connections from existing locations.

4. The standards of documentation, instrument tagging, cable and conductor ferruling,

terminal identification and labeling that apply to the new installation apply equally to

the existing installation which forms part of the modified system.

1.05 SUBMITTALS

A. Furnish submittals as specified in Section 01330 and this Section.

B. General:

1. Instruct all equipment suppliers of submittals and operation and maintenance

manuals of the requirements in this Section.

2. Furnish the submittals required by each section in the Electrical Specifications.

3. Adhere to the wiring numbering scheme specified in Section 16075 throughout the

Project:

a. Uniquely number each wire.

b. Wire numbers must appear on all Equipment Drawings.

4. Use equipment and instrument tags, as indicated on the Drawings, for all submittals.

5. List of manufacturer’s recommended spare parts.




16050 - 8

C. Seismic requirements:

1. Provide electrical equipment with construction and anchorage to supporting

structures designed to resist site seismic loads as specified in Section 01612.

2. For equipment installed in structures designated as seismic design category C, D, E

or F, prepare and submit the following:

a. Statement of seismic qualification, and special seismic certification:

1) “Statement of seismic qualification:” Provide manufacturer’s statement that

the equipment satisfies the seismic design requirements of the building code

indicated in Section 01410, including the requirements of ASCE 7, Chapter

13.

2) “Special seismic certification:” Provide manufacturer’s certification that the

equipment, when subjected to shake table testing in accordance with ICC-

ES AC 156, meets the “Post-Test Functional Compliance Verification”

requirements of ICC-ES AC 156 for “Components with Ip = 1.5.” Compliance

shall include both operability and containment of hazardous materials as

appropriate to the unit being tested.

b. Substantiating test data: With seismic qualification and special seismic

certification statements, submit results of testing in accordance with ICC-

ES AC 156.

c. Anchoring design calculations and details:

1) Submit project-specific drawings and supporting calculations, prepared and

sealed by a professional engineer licensed in the state where the Project is

being constructed, and showing details for anchoring electrical equipment to

its supports and for anchoring supports provided with the equipment to the

structure. Prepare calculations in accordance with the requirements of

Section 01612.

3. Exemptions: A “statement of seismic qualification” and a “special seismic

certification” are not required for the following equipment:

a. Temporary or moveable equipment.

b. Equipment anchored to the structure and having a total weight of 20 pounds or

less.

c. Distribution equipment anchored to the structure and having a total unit weight

of 5 pounds per linear foot, or less.

D. Submittal organization:

1. First page:

a. Specification section reference.

b. Name and telephone number of individuals who reviewed submittal before

delivery to Engineer.

c. Name and telephone number of individual who is primarily responsible for the

development of the submittal.

d. Place for Contractor’s review stamp and comments.

2. Next pages:

a. Provide confirmation of specification compliance in a tabular form that

individually lists each specification section, paragraph, and sub-paragraphs and

unequivocally states compliance with said requirement or takes exception to the




16050 - 9

requirement and lists the reason for said exception and offers alternative means

for compliance.

b. Include a response in writing to each of the Engineer’s comments or questions

for submittal packages which are re-submitted:

1) In the order that the comments or questions were presented throughout the

submittal.

2) Referenced by index section and page number on which the comment

appeared.

3) Acceptable responses to Engineer’s comments are either:

a) Engineer’s comment or change is accepted and appropriate changes are

made.

b) Explain why comment is not accepted or requested change is not made.

c) Explain how requirement will be satisfied in lieu of comment or change

requested by Engineer.

4) Any re-submittal, which does not contain responses to the Engineer’s

previous comments shall be returned for Revision and Re-submittal.

5) No further review by the Engineer will be performed until a response for

previous comments has been received.

3. Remaining pages:

a. Actual submittal data:

1) Organize submittals in exactly the same order as the items are referenced,

listed, and/or organized in the specification section.

2) For submittals that cover multiple devices used in different areas under the

same specification section, the submittal for the individual devices must list

the area where the device is intended to be used.

E. Submittal requirements:

1. Furnish submittals that are fully indexed with a tabbed divider for every component.

2. Sequentially number pages within the tabbed sections. Submittals and operation and

maintenance manuals that are not fully indexed and tabbed with sequentially

numbered pages, or are otherwise unacceptable, will be returned without review.

3. Edit all submittals and operation and maintenance manuals so that the submittal

specifically applies to only the equipment furnished.

a. Neatly cross out all extraneous text, options, models, etc. that do not apply to the

equipment being furnished, so that the information remaining is only applicable

to the equipment being furnished.

4. Submit copies of shop drawings, and product data:

a. Show dimensions, construction details, wiring diagrams, controls, manufacturers,

catalog numbers, and all other pertinent details.

5. Where submittals are required, provide a separate submittal for each specification

section. In order to expedite construction, the Contractor may make more than 1

submittal per specification section, but a single submittal may not cover more than 1

specification section:

a. The only exception to this requirement is when 1 specification section covers the

requirements for a component of equipment specified in another section. (For

example, circuit breakers are a component of switchgear. The switchgear




16050 - 10

submittal must also contain data for the associated circuit breakers, even though

they are covered in a different specification section.)

6. Exceptions to Specifications and Drawings:

a. Include a list of proposed exceptions to the Specifications and Drawings along

with a detailed explanation of each.

b. If there is insufficient explanation for the exception or deviation, the submittal will

be returned requiring revision and re-submittal.

c. Acceptance of any exception is at the sole discretion of the Engineer.

1) Provide all items (materials, features, functions, performance, etc.) required

by the Contract Documents that are not accepted as exceptions.

d. Replace all items that do not meet the requirements of the Contract Documents,

which were not previously accepted as exceptions, even if the submittals

contained information indicating the failure to meet the requirements.

7. Specific submittal requirements:

a. Shop drawings:

1) Required for materials and equipment listed in this and other sections.

2) Furnish sufficient information to evaluate the suitability of the proposed

material or equipment for the intended use, and for compliance with these

Specifications.

3) Shop drawings requirements:

a) Front, side, and, rear elevations, and top and bottom views, showing all

dimensions.

b) Locations of conduit entrances and access plates.

c) Component layout and identification.

d) Schematic and wiring diagrams with wire numbers and terminal

identification.

e) Connection diagrams, terminal diagrams, internal wiring diagrams,

conductor size, etc.

f) Anchoring method and leveling criteria, including manufacturer’s

recommendations for the Project site seismic criteria.

g) Weight.

h) Finish.

i) Nameplates:

(1) As specified in Section 16075.

j) Temperature limitations, as applicable.

b. Product data:

1) Submitted for non-custom manufactured material listed in this and other

sections and shown on shop drawings.

2) Include:

a) Catalog cuts.

b) Bulletins.

c) Brochures.

d) Quality photocopies of applicable pages from these documents.




16050 - 11

e) Identify on the data sheets the Project name, applicable specification

section, and paragraph.

f) Identify model number and options for the actual equipment being

furnished.

g) Neatly cross out options that do not apply or equipment not intended to

be supplied.

c. Detailed sequence of operation for all equipment or systems.

F. Operation and maintenance manuals:


2. Furnish the Engineer with a complete set of written operation and maintenance

manuals 4 weeks before energization start-up and/or commissioning.

3. Additional operation and maintenance manual requirements:

a. Completely index manuals with a tab for each section:

1) Each section containing applicable data for each piece of equipment, system,

or topic covered.

2) Assemble manuals using the approved shop drawings, and include, the

following types of data:

a) Complete set of 11-inch by 17-inch drawings of equipment.

b) Complete set of 11-inch by 17-inch drawings of the control system.

c) Complete set of control schematics.

d) Complete parts list for all equipment being provided.

e) Catalog data for all products or equipment furnished.

G. Material and equipment schedules:

1. Furnish a complete schedule and/or matrix of all materials, equipment, apparatus,

and luminaries that are proposed for use:

a. Include sizes, names of manufacturers, catalog numbers, and such other

information required to identify the items.

H. Schedule of values:

1. In addition to completing all items referred to in the schedule of values,

Section 01292, submit per unit material and labor costs used in developing the final

bid for the electrical system, for the express purpose of pricing and cost justification

for any proposed change orders. In addition to the items shown on the schedule of

values, provide per unit material and labor costs for conduit and wire installation for

specific types, sizes, and locations as indicated on the Drawings and Conduit

Schedule. It is the responsibility of the electrical subcontractor to prove to the

Engineer’s satisfaction that said per unit costs were used in the development of the

final Bid amount.

I. Roof penetrations:

1. Submit details of all portions of the electrical installation that penetrate the roof.

Include details showing support of the penetrating component, and the sealing

means to be utilized.




16050 - 12

J. Record Documents:

1. Furnish as specified in Section 01770.

2. Provide Record Documents of all Electrical Drawings.

3. Record Drawing requirements:

a. Update Record Drawings weekly.

b. Record Drawings must be fully updated as a condition of the monthly progress

payments.

c. Submit Record Drawings upon completion of the Work for final review.

d. Clearly and neatly show all changes including the following:

1) All existing pipe, conduit, wire, instruments or other structures encountered

or uncovered during construction.

4. Shop drawings:

a. Upon completion of the Work, update all shop drawings to indicate the final as-

built configuration of the systems:

1) Provide as-built shop drawings for all electrical equipment on 11-inch by 17-

inch using Bond paper.

2) Provide electronic copies of these documents on CD-ROM disks in Auto-Cad

by Autodesk and PDF. Verify the current version of Auto-CAD with the District.

Size all drawings to be readable and legible on 11-inch by 17-inch media.

b. Furnish written information prepared specifically for this Project using Microsoft

Word 2016 and PDF and printed on 8.5-inch by 11-inch plain bond paper:

1) Provide electronic copies of these documents on CD-ROM disks.

5. Review and corrections:

a. Correct any record documents or other documents found to be incomplete, not

accurate, of poor quality, or containing errors.

b. Promptly correct and re-submit record documents returned for correction.

K. Test reports:


2. Include the following:

a. A description of the test.

b. List of equipment used.

c. Name of the person conducting the test.

d. Date and time the test was conducted.

e. All raw data collected.

f. Calculated results.

g. Each report signed by the person responsible for the test.

3. Additional requirements for acceptance test reports are specified in Section 16950.

L. Calculations:

1. Where required by specific Electrical Specifications:

a. Because these calculations are being provided by a registered professional

engineer, they will be reviewed for form, format, and content but will not be

reviewed for accuracy and calculation means.




16050 - 13

M. Factory acceptance test:


2. Include complete test procedure and all forms to be used during test.


A. Furnish all equipment listed by and bearing the label of UL or of an independent testing

laboratory acceptable to the Engineer and the Authority Having Jurisdiction.

B. System supplier responsibilities:

1. Requirements as specified in the Instrumentation and Control Specifications.

2. System supplier:

a. Due to the critical and complex technical requirements of this Project, all Work

(materials, equipment, products, submittals, labor, services, etc.) specified in the

Electrical, and Instrumentation and Control Specifications, and shown on the

Electrical and Instrumentation Drawings is to be furnished by a single system

supplier who has single source responsibility for both the process control and

instrumentation systems and the electrical power system.

3. Contractual relationship:

a. Form a contractual relationship between the electrical subcontractor and the

ICSC.

b. Requirements for the first tier subcontractor:

1) Contract directly with the Contractor.

2) Be either the electrical subcontractor or the ICSC.

c. Requirements for the second tier subcontractor:

1) A division of the first tier subcontractor, or

2) A joint venture with the first tier subcontractor, or

3) A subcontractor to the first tier subcontractor.

d. The system supplier manages, directs, and supervises all of the Work of its

second tier subcontractor. The system supplier is solely responsible for the entire

electrical and instrumentation system, including, but not limited to, all Electrical,

Instrumentation, and Process Contract Drawings, Electrical Specifications, and

Instrumentation and Control Specifications:

1) Provide any additional conduit, wire, etc.

2) Any additional I/O, programming, screens, interface devices needed by the

system supplier are to be provided by the electrical subcontractor or the

ICSC, under the above outlined working agreement.

3) Ensure compatibility between the PCIS system and the electrical system

being installed.

1.07 DELIVERY, STORAGE, AND PROTECTION

A. Shipping precautions:

1. After completion of shop assembly and successful factory testing, pack all equipment

in protective crates, and enclose in heavy duty polyethylene envelopes or secured

sheeting to provide complete protection from damage, dust, and moisture.

2. Place dehumidifiers, when required, inside the polyethylene coverings.




16050 - 14

3. Skid-mount the equipment for final transport.

4. Provide lifting rings for moving without removing protective covering.

5. Display boxed weight on shipping tags together with instructions for unloading,

transporting, storing, and handling at the job site.

B. Delivery and inspection:

1. Deliver products in undamaged condition, in manufacturer’s original container or

packaging with identifying labels intact and legible. Include date of manufacture on

label.

C. Special instructions:

1. Securely attach special instructions for proper field handling, storage, and installation

to each piece of equipment before packaging and shipment.

1.08 PROJECT OR SITE CONDITIONS

A. Site conditions:

1. Provide an electrical, instrumentation and control system, including all equipment,

raceways and any other components required for a complete installation that meets

the environmental conditions for the Site as specified in the General Requirements

and below.

2. Seismic load resistance:

a. Provide electrical equipment with construction and anchorage to supporting

structures designed to resist site seismic loads as specified in Section 01612.

3. Wind load resistance:

a. Provide electrical equipment with construction and anchorage to supporting

structures designed to resist site wind loads as specified in Section 01612.

4. Altitude, temperature and humidity:

a. As specified in Section 01610.

b.a. Provide all electrical components and equipment fully rated for continuous

operation at this altitude, with no additional de-rating factors applied.

c.b. Provide additional temperature conditioning equipment to maintain all

equipment in non-conditioned spaces subject to these ambient temperatures,

with a band of 10 degrees Fahrenheit above the minimum operating temperature

and 10 degrees Fahrenheit below maximum operating temperature, as

determined by the equipment manufacturer’s guidelines:

1) Provide all power conduits wiring for these devices (e.g. heaters, fans, etc.)

whether indicated on the Drawings or not.

5. Site security:

a. Abide by all security and safety rules concerning the Work on the Site, as

specified in Section 01329.




16050 - 15

6. Outdoor installations:

a. Provide electrical, instrumentation and control equipment suitable for operation

in the ambient conditions where the equipment is located.

b. Provide heating, cooling, and dehumidifying devices incorporated into and

included with electrical equipment, instrumentation and control panels to

maintain the enclosures within the rated environmental operating ranges as

specified in this Section for the equipment:

1) Provide all wiring necessary to power these devices.

B. Provide enclosures for electrical, instrumentation and control equipment, regardless of

supplier or subcontractor furnishing the equipment, that meet the requirements outlined

in NEMA Standard 250 for the following types of enclosures:

1. NEMA Type 1: Intended for indoor use, primarily to provide a degree of protection

from accidental contact with energized parts or equipment.

2. NEMA Type 4: Intended for indoor or outdoor use, primarily to protect equipment

from exposure to windblown dust and rain, splashing or hose directed water, ice

formation and freezing.

3. NEMA Type 4X: Made from corrosion resistant materials 316 stainless steel and are

intended for indoor or outdoor use, primarily to protect equipment from exposure to

windblown dust and rain, splashing or hose directed water, ice formation and

freezing, and corrosion.

4. NEMA Type 12: Intended for indoor use, primarily to provide a degree of protection

from dust, falling dirt and dripping non-corrosive liquids.

5. NEMA Type 6: Rated for submergence.

6. NEMA Type 6P: Rated for prolonged submergence.

7. NEMA Type 7: Intended for installation in locations where explosive or combustible

gas or vapors may be present (Class I Division 1 or Class I Division 2) meeting the

requirements outlined in Section 16052.

8. NEMA Type 8: Intended for installation in either indoor or outdoor locations where

explosive or combustible gas or vapors may be present (Class I Division 1 or Class I

Division 2) and the equipment is oil-immersed, meeting the requirements outlined in

Section 16052.

C. Plant area Electrical Work requirements:

1. Provide all Electrical Work in accordance with the following table, unless otherwise

specifically indicated on the Drawings:

2. Provide stainless steel NEMA 4X enclosures and supports, and PCS conduit type for

all Electrical work not included in the following table unless otherwise indicated on

the Drawings. Conduit type definitions are listed under 16130 Conduit, 1.03B.

3. Modify conduit runs as specified in Section 16130.

PLANT AREA

NEMA

ENCLOSURE

TYPE

EXPOSED

CONDUIT

TYPE

ENVIRONMENT

W = WET

D = DAMP

C = CLEAN/DRY

X = CORROSIVE

H = HAZARDOUS

SUPPORT

MATERIALS

ANCHOR

MATERIALS

Electrical/Control Rooms NEMA 12 GRC C SST SST

Outdoor NEMA 4X PCS W SST SST




16050 - 16

1.09 SEQUENCING (NOT USED)

1.10 SCHEDULING

A. General:

1. As specified in Section 01756 Testing, Training, and Facility Startup.

2. Testing requirements are specified in Section 01756 Testing, Training, and Facility

Startup, Section 16950 Field Electrical Acceptance Tests, and other sections.

3. General scheduling requirements are specified in Section 01324 Construction

Schedule.

4. Work restrictions and other scheduling requirements are specified in Section 01140

Work Restrictions.

5. Testing and process Start-up requirements as specified in Section 01756 Testing,

Training, and Facility Startup.

B. Pre-submittal conference:

1. Before producing any submittals, schedule a pre-submittal conference for the

purposes of reviewing the entire Project, equipment, control philosophy, schedules,

and submittal requirements.

2. The Contractor, instrumentation and control subcontractor, electrical subcontractor,

all suppliers, and individual equipment manufacturers furnishing major pieces of

equipment must attend, including but not limited to:

a. Vendor control panels

b. Electrical equipment shelter

c. Local control stations

d. Disconnect switches

e. Variable frequency drives

f. Lighting

C. Factory acceptance testing:

1. Where factory acceptance testing is required for equipment covered by these

Specifications, notify the Engineer in writing when the equipment is completed and

ready for factory inspection and testing:

a. Indicate the desired dates for inspection and testing.

b. Schedule the FAT after approval of the FAT procedures submittal:

1) Submit a copy of the test procedures including all forms at least 21 days

before any scheduled test date.

2) Notify the Engineer of the scheduled tests a minimum of 15 days before the

date of the test.

1.11 WARRANTY

A. Warrant the Electrical Work as specified in Document 00700:

1. Provide additional warranty as specified in the individual Electrical Specifications.




16050 - 17

1.12 SYSTEM START-UP

A. Replace or modify equipment, software, and materials that do not achieve design

requirements after installation in order to attain compliance with the design

requirements:

1. Following replacement or modification, retest the system and perform additional

testing to place the complete system in satisfactory operation and obtain compliance

acceptance from the Engineer.

1.13 MAINTENANCE

A. Before Substantial Completion, perform all maintenance activities required by any

sections of the Specifications including any calibrations, final adjustments, component

replacements or other routine service required before placing equipment or systems in

service.

B. Furnish all spare parts as required by other sections of the Specifications.

PRODUCTS

2.01 MANUFACTURERS

A. Provide similar items of same manufacturer throughout the electrical and

instrumentation portion of the Project.

B. Allowable manufacturers are specified in individual Electrical Specifications.

2.02 MATERIALS

A. Furnish all materials under this Contract that are new, free from defects, and standard

products produced by manufacturers regularly engaged in the production of these

products and that bear all approvals and labels as required by the Specifications.

B. Provide materials complying with the applicable industrial standard as specified in

Document 00700.

C. Stainless steel:

1. Where stainless steel is indicated or used for any portion of the Electrical Work,

provide a non-magnetic, corrosion-resistant alloy, ANSI Type 316, satin finish.

2. Provide exposed screws of the same alloys.

3. Provide finished material free of any burrs or sharp edges.

4. Use only stainless steel hardware, when chemically compatible, in all areas that are

or could be in contact with corrosive chemicals.

5. Use stainless steel hardware, when chemically compatible, in all chemical areas or

areas requiring NEMA Type 4X construction.

6. Do not use stainless steel in any area containing chlorine, gas or solution, chlorine

products or ferric chloride.




16050 - 18


A. Provide all equipment that is new, free from defects, and standard products produced by

manufacturers regularly engaged in the production of these products.

B. Arrange with all manufacturers of the electrical equipment, to allow the Owner and

Engineer to inspect and witness the testing of the equipment at the site of fabrication:

1. Testing includes the cabinets, special control systems, power equipment, and other

pertinent systems and devices.

C. Factory testing is specified in the individual sections of the Electrical Specifications.

EXECUTION

3.01 EXAMINATION

A. The electrical subcontractor is encouraged to examine the premises completely before

bidding.

B. The electrical subcontractor shall examine the bid documents completely before bidding.

C. It is the electrical subcontractor's responsibility to be fully familiar with the existing

conditions and local requirements and regulations.

D. Review the site conditions and examine all shop drawings for the various items of

equipment in order to determine exact routing and final terminations for all wiring and

cables.

E. Provide a complete electrical system:

1. Install all extra conduits, cables, and interfaces as may be necessary to provide a

complete and operating electrical and PCIS system.

3.02 INSTALLATION

A. Equipment locations shown on Electrical Drawings may change due to variations in

equipment size or minor changes made by others during construction:

1. Verify all dimensions indicated on the Drawings:

a. Actual field conditions govern all final installed locations, distances, and levels.

2. Review all Contract Documents and approved equipment shop drawings and

coordinate Work as necessary to adjust to all conditions that arise due to such

changes.

3. Make minor changes in location of equipment before rough in, as directed by the

Owner or Engineer.

4. Provide a complete electrical system:

a. Install all extra conduits, cables, and interfaces as may be necessary to provide a

complete and operational electrical, PCIS, and HVAC system.

B. Submit a Request for Information for any conflict between the Drawings and

Specifications prior to installation.




16050 - 19

C. Install the equipment in accordance with the accepted installation instructions and

anchorage details to meet the seismic and wind load requirements at the Project site.

D. Cutting and patching:

1. Perform all cutting, patching, channeling, core drilling, and fitting required for the

Electrical Work, except as otherwise directed:

a. Secure the permission of the Engineer before performing any operation likely to

affect the strength of a structural member such as drilling, cutting or piercing:

1) Before cutting, channeling, or core drilling any surface, ensure that no

penetration of any other systems will be made:

a) Verify that area is clear and free of conduits, cables, piping, ductwork,

post-tensioning cables, etc.

b) Use tone-locate system or X-ray to ensure that area is clear of

obstructions.

b. Review the complete Drawing set to ensure that there are no conflicts or

coordination problems before cutting, channeling, or core drilling any surface.

2. Perform all patching to the same quality and appearance as the original work. Employ

the proper tradesmen to secure the desired results. Seal around all conduits, wires,

and cables penetrating walls, ceilings, and floors in all locations with a fire stop

material, typically:

a. 3MCP 25WB+Caulk.

b. 3MFire BarrierPutty.

3. Seal around conduit penetrations of below grade walls with a waterproof, non-shrink,

non-metallic grout, unless otherwise indicated on the typical installation details:

a. Use the installation details indicated on the Drawings as a guide for acceptable

sealing methods.

E. Install all conduits and equipment in such a manner as to avoid all obstructions and to

preserve headroom and keep openings and passageways clear:

1. Install all conduits and equipment in accordance with working space requirements as

outlined in the NEC.

a. This includes any panel, disconnect switch or other equipment that can be

energized while open exposing live parts regardless of whether it is likely to

require examination or has serviceable parts.

2. Where the Drawings do not show dimensions for locating equipment, install

equipment in the approximate locations indicated on the Drawings.

a. Adjust equipment locations as necessary to avoid any obstruction or

interferences.

3. Where an obstruction interferes with equipment operation or safe access, relocate

the equipment.

4. Where the Drawings do not indicate the exact mounting and/or supporting method to

be used, use materials and methods similar to the mounting details indicated on the

Drawings.




16050 - 20

F. Earthwork and concrete:

1. Install all trenching, shoring, concrete, backfilling, grading and resurfacing associated

with the Electrical Work:

a. Requirements as specified in the Contract Documents.

G. Roof penetrations:

1. Seal conduit penetrations in accordance with roofing manufacturer’s instructions.

H. Terminations:

1. Provide and terminate all conductors required to interconnect power, controls,

instruments, panels, and all other equipment.

I. Miscellaneous installation requirements:

1. In case of interference between electrical equipment indicated on the Drawings and

the other equipment, notify the Engineer as specified in Document 00700.

2. Location of manholes and pull-boxes indicated on the Drawings are approximate.

Coordinate exact location of manholes and pull-boxes with Mechanical and Civil

Work.

3. Provide additional manholes or pull-boxes to those shown where they are required to

make a workable installation.

J. Labeling:

1. Provide all nameplates and labels as specified in Sections 16075.

K. Equipment tie-downs:

1. Anchor all instruments, control panels, and equipment by methods that comply with

seismic and wind bracing criteria, which apply to the Site.

2. All control panels, VCPs, LCPs, RTUs, PCMs, etc., must be permanently mounted and

tied down to structures in accordance with the Project seismic criteria.

3.03 TESTING AND FACILITY STARTUP

A. As specified in Section 01756 Testing, Training, and Facility Startup

B. For Owner and Engineer witnessed FAT:

1. The Contractor is responsible for the Owner’s and Engineer’s costs associated with

FAT as specified in individual equipment Sections.


A. Inspection:

1. Allow for inspection of electrical system installation as specified in Section 01450.

2. Provide any assistance necessary to support inspection activities.

3. Engineer inspections may include, but are not limited to, the following:

a. Inspect equipment and materials for physical damage.

b. Inspect installation for compliance with the Drawings and Specifications.

c. Inspect installation for obstructions and adequate clearances around equipment.




16050 - 21

d. Inspect equipment installation for proper leveling, alignment, anchorage, and

assembly.

e. Inspect equipment nameplate data to verify compliance with design

requirements.

f. Inspect raceway installation for quality workmanship and adequate support.

g. Inspect cable terminations.

h. Schedule inspection of all mounting of electrical devices and all penetration and

connections to structures.

4. Inspection activities conducted during construction do not satisfy inspection or

testing requirements specified in Section 16950.

B. Field testing:

1. Notify the Engineer when the Electrical Work is ready for field acceptance testing.

2. Perform the acceptance tests as specified in Section 16950.

3. Record results of the required tests along with the date of test:

a. Use conduit identification numbers to indicate portion of circuit tested.

C. Workmanship:

1. Leave wiring in panels, manholes, boxes, and other locations neat, clean, and

organized:

a. Neatly coil and label spare wiring lengths.

b. Shorten, re-terminate, and re-label excessive used as well as spare wire and

cable lengths, as determined by the Engineer.

3.05 CLEANING

A. As specified in Section 01770.

B. Remove all foreign material and restore all damaged finishes to the satisfaction of the

Engineer and Owner.

C. Clean and vacuum all enclosures to remove all metal filings, surplus insulation and any

visible dirt, dust or other matter before energization of the equipment or system start-up:

1. Use of compressors or air blowers for cleaning is not acceptable.

D. Clean and re-lamp all new and existing luminaires that were used in the areas affected

by the construction and return all used lamps to the Owner.

E. As specified in other sections of the Contract Documents.

3.06 DEMONSTRATION AND TRAINING

A. Furnish all personnel and equipment necessary to conduct the demonstration and

training requirements as specified in the individual sections.




16050 - 22

3.07 PROTECTION

A. Protect all Work from damage or degradation until Substantial Completion.

B. Maintain all surfaces to be painted in a clean and smooth condition.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Hazardous Classified Area Construction



16052 - 1

SECTION 16052

HAZARDOUS CLASSIFIED AREA CONSTRUCTION

GENERAL

1.01 SUMMARY


1. Executing and completing Work in hazardous and/or classified areas as defined by

the NEC Articles 500 through 516

2. NFPA 820, and as indicated on the Drawings and specified in the Specifications.

B. Related Sections

1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all.


subcontractors, suppliers, and other individuals or entities performing or

furnishing any of Contractor’s Work.

1.02 REFERENCES

A. As specified in Section 16050, Common Work Results for Electrical.

1.03 DEFINITIONS



1. For the purposes of these Specifications, the terms “Hazardous” and “Classified”

will be considered synonymous.

1.04 SYSTEM DESCRIPTION (NOT USED)

A. SUBMITTALS

B. Furnish submittals as specified in Section 01330, Submittal Procedures and Section

16050, Common Work Results for Electrical.



B. Regulatory requirements:

1. All wiring in hazardous and/or classified locations shall comply with all applicable

articles of the NEC, in particular Articles 500 through 516.

2. Except as modified in Articles 500 through 516, all other applicable rules

contained in the NEC shall apply to electric equipment and wiring installed in

hazardous and/or classified locations.




16052 - 2

3. All devices used in Class I Division 1 or Division 2 areas must have visible

manufacturer installed nameplates specifically stating the Class, Division, and

Group for which the device is approved.




A. A list of hazardous areas is specified in Section 16050, Common Work Results for

Electrical and indicated on the Drawings.

PRODUCTS

2.01 COMPONENTS

A. Conduit and sealing fittings:

1. As specified in Section 16130, Common Work Results for Electrical.

B. Conduit boxes and bodies:

1. As specified in Section 16134, Boxes.

C. Wiring devices:

1. As specified in Section 16140, Wiring Devices.

EXECUTION

3.01 INSTALLATION


B. Conduit installation:

1. As specified in Section 16130, Conduits.

2. Wrench tighten all conduit joints to minimize sparking when fault current flows

through the conduit system.

3. Make all conduit connections so that there is a minimum of 5 threads fully

engaged in the connection.

4. Flexible conduit:

a. Class I Division 1 hazardous areas:

1) Approved and marked suitable for Class I Division 1.

2) Listed for compatibility with the group type atmosphere where used.

b. Class I Division 2 areas:

1) Liquidtight metal conduit with approved fittings.

c. Maximum length as specified in Section 16130, Conduits.

C. Sealing fittings:

1. Provide an approved seal, no more than 18 inches from the enclosure, for all

conduits entering an enclosure containing switches, circuit breakers, fuses, relays,




16052 - 3

resistors, or any other apparatus which may produce arcs, sparks, or high

temperatures:

a. Only explosion proof unions, couplings, elbows, capped elbows, and conduit

bodies like “L”, “T”, and “X” may be installed between the sealing fitting and

the enclosure.

2. Provide entire assemblies approved for Class I locations for self- sealing or factory

sealed assemblies where the equipment that may produce arcs, sparks, or high

temperatures is located in a compartment separate from the compartment

containing splices or taps, and an integral seal is provided where conductors pass

from one compartment to the other:

a. Seals are required in all conduit connections to the compartment containing

splices and must be within 18 inches of the enclosure.

3. Install a conduit seal within 18 inches of the boundary in each conduit run

entering or leaving a classified location. No union, coupling, box, or fitting is

allowed in the conduit between the sealing fitting and the point at which the

conduit leaves the classified location.

4. For underground conduits entering or leaving a classified location or between

Class I Division 1 and Division 2 locations:

a. Provide a conduit seal at both points where the conduit emerges from the

ground:

1) Place the conduit seal within 18 inches of finished grade.

2) No union, coupling, box, or fitting is allowed in the conduit system between

the seal fitting and the point at which the conduit enters the ground.

5. Separate all conductors within the conduit system and seal using an approved

packing dam installed to both hold the sealing compound and to maintain the

separation between the wires:

a. Remove the outer jacket of multi-conductor non-shielded cables in the area of

the sealing fitting and separate each conductor from the cable and seal

individually.

6. Install seals with drains in all electrical control stations, low points of conduit or

any place where moisture may condense and accumulate.

7. Install the sealing compound with a minimum thickness of 5/8 inch or the trade

size of the conduit, whichever is greater.

8. All motors, actuators, and instrument transmitters required to have conduit seals

shall have a union installed between the seal and the respective motor, actuator,

or instrument transmitter. This will permit the motor, actuator, or transmitter to

be disconnected or replaced without disturbing the wiring or conduit seal.

D. Boxes and fittings:

1. Class I Division 1 areas:

a. Utilize threaded connections for all metallic boxes, fittings, and joints to the

conduit system.


a. Provide approved grounding bushings on conduits entering and exiting

metallic boxes to bond the conduits together.




16052 - 4

E. Outlet boxes and bodies:

1. Provide conduits bodies and boxes suitable for the conduit system as specified in

Section 16130, Conduits.


a. Boxes not containing arcing parts:

1) Material and NEMA ratings as specified in Section

16050, Common Work Results for Electrical.

2) Pressed metal boxes are not allowed.

b. Provide heavy duty cast construction type conduit fittings and joints:

3) Explosion proof rated fittings and joints are not

necessary.

c. Any enclosure containing arcing parts, etc. shall have all construction

associated with the enclosure, conduit system, etc. conforming to Class I

Division 1 construction.

F. Motor connections:

1. Conduit installation in Class I Division 1 and Class I Division 2 locations for motors

that contain arcing parts, shall proceed as follows:

a. First - Conduit.

b. Second - Explosion proof flexible coupling.

c. Third - Sealing fitting.

d. Fourth - Explosion proof union.

e. Fifth - Connection to the motor terminal box.

2. Wiring connections to motor leads shall be as specified in Section 16150, Low

Voltage Wire Connections.

3. Bond the non-current-carrying metal parts of equipment, raceways and other

enclosures as required by the NEC to ensure electrical continuity.

G. Grounding

1. A grounding conductor shall be provided in all raceways, junction boxes, and

enclosures located within all Class 1 Division 1 and Class 1 Division 2 locations.


A. As specified in Section 01756, Testing, Training and Facility Startup.



B. Obtain inspection and approval from the Engineer before and after each seal is

poured.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Grounding and Bonding



16060 - 1

SECTION 16060

GROUNDING AND BONDING

GENERAL

1.01 SUMMARY


1. Grounding electrodes.

2. Grounding electrode conductors.

3. Equipment grounding conductors.

4. Main bonding jumper.

5. Ground connections.

6. General requirements for grounding.











a. Section 01330 - Submittal Procedures.

b. Section 16050 - Common Work Results for Electrical.

c. Section 16950 - Field Electrical Acceptance Tests.

1.02 REFERENCES


B. ASTM International (ASTM):

1. B 3 - Standard Specification for Soft or Annealed Copper Wire.

2. B 8 - Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard,

Medium-Hard, or Soft.

C. Institute of Electrical and Electronics Engineers (IEEE):

1. 81 - IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth

Surface Potentials of a Grounding System.

D. Underwriters Laboratories, Inc. (UL):

1. 467 - Ground and Bonding Equipment.




16060 - 2

1.03 DEFINITIONS



A. Ground equipment and raceway systems so that the completed installation conforms to

all applicable code requirements.

B. Provide a complete electrical grounding system as indicated on the Drawings and as

specified including but not limited to:

1. Grounding electrodes.

2. Bonding jumpers.

3. Ground connections.

C. Provide bonding jumpers and wire, grounding bushings, clamps and appurtenances

required for complete grounding system to bond equipment and raceways to equipment

grounding conductors.

D. The ground system resistance (electrode to ground) of the completed installation, as

determined by tests specified in Section 16950, shall be:

1. 5 ohms or less for industrial systems.

2. 1 ohm or less for electrical buildings.

1.05 SUBMITTALS

A. Furnish submittals as specified in Sections 01330 and 16050.

B. Product data:

1. Catalog cut sheets.



B. All grounding components and materials shall be UL listed and labeled.



1.08 WARRANTY







16060 - 3

PRODUCTS

2.01 MANUFACTURERS

A. Compression connectors: One of the following or equal:

1. FCI Burndy.

2. Thomas & Betts.

B. Ground rods: One of the following or equal:

1. Erico.

2. Harger.

3. Conex.

C. Ground cable: One of the following or equal:

1. Nehring.

2. Harger.

3. Southwire.

D. Precast ground well boxes: One of the following or equal:

1. Brooks Products, 3-RT Valve Box.

2. Christy Concrete Products, G12 Valve Box.

2.02 MATERIALS

A. Ground rod:

1. Minimum: 3/4-inch diameter, 10 feet long.

2. Uniform 10 mil covering of electrolytic copper metallically bonded to a rigid steel

core:

a. The copper-to-steel bond shall be corrosion resistant.

3. In accordance with UL 467.

4. Sectional type joined by threaded copper alloy couplings.

5. Fit the top of the rod with a threaded coupling and steel-driving stud.

B. Ground cable:

1. Requirements:

a. Soft drawn (annealed).

b. Concentric lay, coarse stranded in accordance with ASTM B 8.

c. Bare copper in accordance with ASTM B 3.

d. Tin plated copper ground wire shall be used on aluminum cable tray.

2. Size is as indicated on the Drawings, but not less than required by the NEC.

C. Compression connectors:

1. Manufactured of high copper alloy specifically for the particular grounding

application.

2. Suitable for direct burial in earth and concrete.




16060 - 4

3. Identifying compression die number inscription to be impressed on compression

fitting.

D. Equipment grounding conductors:

1. Conductors shall be the same type and insulation as the load circuit conductors:

a. Use 600-volt insulation for the equipment grounding conductors for medium

voltage systems.

2. Minimum size in accordance with the NEC.

E. Grounding electrode conductors:


F. Main bonding jumpers and bonding jumpers:


2.03 ACCESSORIES

A. Precast ground well boxes:

1. Minimum 10 inch interior diameter.

2. Traffic-rated cast iron cover.

3. Permanent “GROUND” marking on cover.

EXECUTION

3.01 INSTALLATION


B. Provide a separate, green insulated, grounding conductor in each raceway independent

of raceway material:

1. Multi-conductor power and control cables shall include an integral green insulated

grounding conductor.

2. Provide a separate grounding conductor in each individual raceway for parallel

feeders.

C. Provide a separate grounding conductor for each motor and connect at motor terminal

box. Do not use bolts securing motor box to frame or cover for grounding connectors:

1. When grounding motors driven by variable frequency drives (VFD) comply with the

requirements of the VFD manufacturer.

D. Provide a grounding type bushing with lug for connection of grounding conductor for

conduits that originate from each motor control center section, switchboard, or

panelboard:

1. Individually bond these raceways to the ground bus in the equipment.

E. Provide grounding type bushings with lug for a connection to a grounding conductor for

all conduits which terminate at a cable tray.




16060 - 5

F. Provide grounding type bushings with lugs for connection of grounding conductor at both

ends of metallic conduit runs. Bond ground bushings to the grounding system.

G. Provide a green insulated wire-grounding jumper from the ground screw to a box

grounding screw and, for grounding type devices, to equipment grounding conductor.

H. Interconnect the secondary switchgear, switchboard, or panelboard neutral bus to the

ground bus in the secondary switchgear, switchboard, or panelboard compartment, only

at service entrance point or after a transformer.

I. Direct buried raceway trench system:

1. Provide a bare copper grounding conductor the entire length of each trench as

indicated on the Drawings and specified in the Specifications.

2. Bond trench system ground conductors together where trenches join, merge,

intersect, or split.

J. Grounding at service (600 V or Less):

1. Connect the neutral to ground only at one point within the enclosure of the first

disconnecting means on the load side of the service transformer.

K. Ground connections:

1. All connections to the ground grid system, the direct buried raceway trench grounding

system, equipment, ground rods, etc., shall be made using compression type

grounding connectors as indicated on the Drawings, UL listed, and labeled for the

application.

2. Make ground connections in accordance with the manufacturer's instructions.

3. Do not conceal or cover any ground connections until the Engineer or authorized

representative has established and provided written confirmation that every

grounding connection is as indicated on the Drawings and specified in the

Specifications.

L. Grounding electrode system:

1. Ground ring:

a. Provide all trenching and materials necessary to install the ground ring as

indicated on the Drawings.

b. Ground ring conductor shall be in direct contact with the earth, or where

embedded, concrete, of the size as indicated on the Drawings.

c. Minimum burial depth 36 inches or as indicated on the Drawings.

d. Re-compact disturbed soils to original density in 6-inch lifts.

2. Ground rods:

a. Locations as indicated on the Drawings.

b. Length of rods forming an individual ground array shall be equal in length.

c. Drive ground rods and install grounding conductors before construction of

concrete slabs and direct buried raceway trench systems.

d. Pre-crimp all ground rods, as recommended by the manufacturer, before

crimping connector to ground rod.




16060 - 6

3. Metal underground water pipe:

a. Bond metal underground domestic water pipe to grounding electrode system.

4. Metal frame of building or structure:

a. Bond metal frame of building or structure to grounding electrode system.

5. Extend grounding conductors through concrete to accessible points for grounding

equipment and electrical enclosures.

6. Install grounding system at each structure where switchgear, motor control centers,

switchboards, panelboards, panels, or other electrical equipment are installed.

7. Bond all metallic equipment likely to become energized.

M. Shield grounding:

1. Shielded instrumentation cable shall have its shield grounded at one end only unless

shop drawings indicate otherwise:

a. The grounding point shall be at the control panel or at the power source end of

the signal carried by the cable.

2. Terminate the shield drain wire on a dedicated terminal block.

3. Insulate the non-grounding end of the shielded cable.

4. Use manufacturer’s terminal block jumpers to interconnect ground terminals.

5. Connection to the panel main ground bus shall be via a green No. 12 conductor to

the main ground bus for the panel.

N. Where indicated on the Drawings, install ground rods in precast ground wells.



B. Measure grounding electrode system resistance to ground in accordance with IEEE 81.

3.03 ADJUSTING

A. Under the direction of the Engineer, add additional parallel connected ground rods

and/or deeper driven rods until the ground resistance measurement meets the specified

resistance requirements:

1. Use of salts, water, or compounds to attain the specified ground resistance is not

acceptable.

3.04 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Hangers and Supports



16070 - 1

SECTION 16070

HANGERS AND SUPPORTS

1.01 GENERAL

1.02 SUMMARY


1. Mounting and supporting electrical equipment and components.











a. Section 01330, Submittal Procedures

b. Section 05190, Mechanical Anchoring and Fastening to Concrete and Masonry

c. Section 09900, Painting and Coating

d. Section 16050, Common Work Results for Electrical

1.03 REFERENCES



1. A 123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and

Steel Products.

2. A 153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.

3. A 240 – Standard Specification for Chromium and Chromium-Nickel Stainless Steel

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

1.04 DEFINITIONS



A. Design requirements:

1. Conform to the requirements of all applicable Building Codes.

2. Demonstrate the following using generally accepted engineering methods:

a. That the anchors to the structure are adequate to resist the loads generated in

accordance with the Building Code and equipment requirements.




16070 - 2

b. That the required load capacity of the anchors can be fully developed in the

structural materials to which they are attached.

3. Design loading and anchoring requirements:

a. As indicated in the Building Code unless otherwise specified.

b. Seismic loading requirements:

1) Freestanding or wall-hung equipment shall be anchored in place by

methods that will satisfy the requirements for the seismic design


c. Wind loading requirements:

2) All exterior freestanding equipment shall be anchored in place by

methods that will satisfy the requirements for wind design specified in

Section 16050.

d. Minimum safety factor against overturning: 1.5.

e. The foundation and structures to which hangers and supports are attached shall

be capable of withstanding all anchor loads.

f. Size the supports for conduit racks and trapezes with 40% spare capacity of the

largest raceway on the rack or trapeze.

B. Performance requirements:

1. Hangers and supports individually and as a system shall resist all weights and code-

required forces without deflections and deformations that would damage the

supporting elements, the equipment supported, or the surrounding construction.

1.06 SUBMITTALS


B. Product data:

1. Supports:

a. Materials.

b. Geometry.

c. Manufacturer.

2. Hardware:

a. Materials.

b. Manufacturer.

C. Shop drawings:

1. Complete dimensioned and scalable shop drawings of all supporting structures,

trapezes, wall supports, etc.

2. Complete anchoring details for equipment, lighting and raceway, supporting

structures, trapezes, wall supports for all equipment in excess of 200 pounds, and all

freestanding supports:

a. Stamped by a professional engineer licensed in the state where the Project is

being constructed.

b. Said submittals, by virtue of the fact that they bear the stamp of a registered

engineer, will be reviewed for general consistency with the requirements




16070 - 3

specified in the Contract Documents, but not for context, accuracy, or method of

calculation.

3. Include data on attachment hardware and construction methods that will satisfy the

design loading and anchoring criteria.

D. Installation instructions:

1. Furnish anchorage instructions and requirements based on the seismic and wind

conditions of the Site:

a. Stamped by a professional engineer licensed in the state where the Project is

being constructed.







1.10 WARRANTY


1.11 SYSTEM STARTUP


1.12 PRODUCTS

1.13 MANUFACTURERS

A. One of the following or equal:

1. Thomas & Betts.

2. Power-Strut.

3. Unistrut.

4. Cooper B-Line.

5. Robroy.

6. Aickinstrut.

1.14 MATERIALS

A. Use materials appropriate for the area as specified in Section 16050.




16070 - 4

B. Stainless steel:

1. Supports:

a. In accordance with ASTM A 240.

b. ANSI Type 316 material.

2. Hardware:

a. ANSI Type 316 material.

C. PVC coated galvanized steel:

1. Supports:

a. Hot dip galvanized steel as specified in this Section.

b. PVC coating thickness of 10 to 20 mils.

2. Hardware:

a. ANSI Type 316 material.

1.15 ACCESSORIES

A. Anchor bolts:

1. As specified in Section 05502 Anchors to Concrete.

1.16 FINISHES

A. Paint and finish all supporting structures as specified in Section 09900.

EXECUTION

2.01 INSTALLATION


B. Mount all raceways, cabinets, boxes, fixtures, instruments, and devices on Contractor-

fabricated racks unless otherwise indicated on the Drawings.

1. Provide the necessary sway bracing to keep trapeze type structures from swaying.

C. Brace and anchor freestanding equipment supports using methods that provide

structural support based on the seismic loads and wind loads:

1. Lateral deflection at top of supports not to exceed support height divided by 240

unless otherwise approved by the Engineer.

D. Provide fabricated steel support pedestals for wall mounted panels that weigh more than

200 pounds:

1. Fabricate pedestals out of welded angle, tube sections, or preformed channel.

2. If the supported equipment is a panel or cabinet, match the supported equipment in

physical appearance and dimensions.

3. Provide auxiliary floor supports for transformers hung from stud walls and weighing

more than 200 pounds.




16070 - 5

4. Mount all equipment, cabinets, boxes, instruments, and devices in damp or wet

locations on minimum of 7/8-inch preformed mounting channel.

a. Mount channel vertically along the length of the device so that water or moisture

may run freely behind the device.

E. Corrosion protection:

1. Isolate dissimilar metals, except where required for electrical continuity.

a. Use neoprene washers, 9-mil polyethylene tape, or gaskets for isolation.

F. Raceway:

1. Furnish all conduit racks and trapeze structures needed to support the raceway from

the structure.

a. Group conduits and position on racks to minimize crossovers.

b. Provide the necessary bracing to keep trapeze type structures from swaying

under loads from cable installation, seismic forces, or wind forces.

c. Cap channel with plastic end caps such as B825-52.

G. Anchoring methods:

1. Solid concrete: Anchor bolts, anchor rods or post-installed anchors as specified in

Section 05502.

2. Metal surfaces: Machine screws or bolts.

3. Hollow masonry units: Post-installed anchors as specified in Section 05502.

H. When supporting devices on metal or wood stud construction, bridge studs with

preformed channel, and mount the devices to the channel.

I. Re-coat all scratches, cuts, and drilled holes in galvanized surfaces with CRC "Zinc-It" or

similar product.

J. Re-coat all drilled holes and cut surfaces on PVC-coated materials.

K. Seal all drilled holes and cut surfaces on fiberglass materials.

L. Use manufacturer supplied strut splice clevises where two or more pieces of strut are

joined.

M. Provide white strut plastic end caps on the ends of all struts.

N. Threaded rods shall not protrude more than ½” beyond the last nut.



2.03 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Electrical Identification



16075 - 1

SECTION 16075

ELECTRICAL IDENTIFICATION

GENERAL

1.01 SUMMARY

A. Section Includes Requirements for:

1. Identifying electrical, instrumentation, and process equipment and components.

2. Material, manufacturing and installation requirements for identification devices.

B. Related Specifications:

1. Section 01330, Submittal Procedures

2. Division 11.

3. Division 13.

4. Division 15.

5. Division 16.

6. Division 17.

1.02 REFERENCES


1.03 DEFINITIONS



A. Nameplates:

1. Provide a nameplate for each piece of mechanical equipment, process equipment,

valve, pump, mixer, feeder, fan, air-handling unit, motor, switch, receptacle,

controller, instrument transducer, instrument power supply, solenoid, motor control

center, starter, panelboard, switchboard, individually mounted or plug-in type circuit

protector or motor controller, disconnect switch, bus duct tap switch, time switch,

relay and for any other control device or major item of electrical equipment, either

located in the field or within panels.

2. Provide all nameplates of identical style, color, and material throughout the facility.

3. Provide new nameplates for all existing equipment worked on in this project.

B. Wire Numbers:

1. Coordinate the wire numbering system with all vendors of equipment so that every

field wire has a unique number associated with it for the entire system:

a. Control and Instrumentation wires and cables shall be assigned a unique

identification number following Owner standards.

b. Wire numbers shall correspond to the terminal block number to which they are

attached in the control panel.

c. Internal panel wires on a common terminal shall have the same wire number.




16075 - 2

d. Multiconductor cables shall be assigned a cable number that shall be attached to

the cable at intermediate pull boxes and stub-up locations beneath freestanding

equipment. All multi-conductor and instrumentation cables shall be identified at

pull points as described above:

1) Label armored multiconductor cable using the conduit number following the

requirements for conduit markers in Section 16130.

e. Spare wiring and terminals shall be tagged as spares.

2. Power cables and wires shall be assigned a unique identification number as specified

by Owner.

1.05 SUBMITTALS

A. Furnish submittals in accordance with Sections 01330 and 16050.

B. Product Data:

1. Nameplates:

a. Color.

b. Size:

1) Outside dimensions.

2) Lettering.

c. Material.

d. Mounting means.

2. Equipment Nameplate Schedule:

a. Show exact wording for each nameplate.

b. Include nameplate and letter sizes.

c. Schedule format shall match equipment nameplate schedule attached at the end

of this section.

d. Submit equipment nameplate schedule for approval before engraving

nameplates.

3. Wire Numbers:

a. Manufacturer’s catalog data for wire labels and label printer.

4. The Contractor shall submit samples for each type of Electrical Identification device

intended to be provided for this project for review and approval. Samples of the

materials and colors proposed for the Work and application instructions shall be

included. Devices shall indicate proposed text sizes, lettering and background

coloring and related information.

C. Record Documents:

1. Update the circuit/raceway block diagrams to reflect the exact quantity of wire

numbers including spares and destination points for all wires.




16075 - 3


A. Schedule a pre-installation conference in accordance with Section 16050 in order to

clearly define the requirements specified for equipment identification:

1. Representatives of the Contractor, Owner, and Engineer shall convene before any

major purchases of cable or conductors and before the installation or termination of

any cables or conductors.



1.08 WARRANTY


1.09 SYSTEM START UP


PRODUCTS

2.01 MANUFACTURERS

A. Nameplates and Signs:

1. One of the following or equal:

a. Brady.

b. Seton.

B. Conductor and Cable Markers:

1. Heat-Shrinkable Tubing:

a. One of the following or equal:

1) Raychem.

2) Brady.

3) Thomas & Betts.

4) Kroy.

2. Marker Printer:


1) Brady XC Plus.

C. Conduit and Raceway Markers:


a. Panduit.

b. Almetek.




16075 - 4

2.02 MATERIALS

A. Nameplates:

1. General:

a. Identification tags shall utilize the Owner standard numbering system for

equipment supplied and installed as part of this project. Identification tags

installed for outdoor equipment shall be rated for weatherproof type.

b. When identifying a power source for equipment, the tag shall include the source

name and circuit or compartment number (i.e., “100MCC0101-4F” or

“100IP0101, CKT. #1”).

c. For all equipment, identification shall include the descriptive name on the first

line, the District’s standard tag number on the second line and the power source

on the third line (e.g.,

Secondary Clarifier 7 RAS Pump #1

46P1801

Power Source 100MCC0101-4F).

d. Text shall be centered on all nameplates and identification devices.

2. Electrical Equipment:

a. Disconnect Switches: Each local power disconnect switch and circuit breaker for

motors, instrument transmitters, controllers, and other equipment shall be

identified with a phenolic nameplate. The nameplate shall identify the load

served by equipment name and tag number, and the power source. Nameplates

shall be not less than 1 inch high with lettering not smaller than 1/4 inch.

Nameplates shall be attached using self-tapping S.S. screws.

b. Switchgear and MCC: Each switchgear/MCC shall be identified with a phenolic

nameplate (e.g. “100SWGR0101” or “100MCC0101”). Each switchgear/MCC

compartment/bucket shall be identified with a phenolic nameplate (e.g., “1A” or

“4F”). The nameplate shall identify the load served by name and tag number.

Stand-alone starters, drives, and similar equipment shall also identify the power

source for the starter, drive, etc. Nameplates shall be attached using S.S. self-

tapping screws. Nameplates shall be not less than 2.25 inches high, with 1-inch

high lettering and 1/2-inch-high tag number lettering.

c. Switchgear/MCC compartments/buckets, VFDs, enclosed starter panels, and

similar electrical equipment: Each compartment/bucket shall be identified with a

phenolic nameplate for the load it serves (e.g., “Secondary Clarifier 7 RAS Pump

#1, 46P1801”). Stand-alone starters, drives, and similar equipment shall also

identify the power source for the starter, drive, etc. Nameplates shall be attached

using S.S. self-tapping screws. Nameplates shall be not less than 2 inches high,

with 1/2-inch-high lettering and 1/2-inch-high tag number lettering.




16075 - 5

d. Local Control Panels (LCP), Control Stations (CS), and field instruments: Each

LCP/CS/Field instrument shall include a nameplate on the enclosure face

identifying the panel name and tag number. Include the power source for each

panel. Each panel-mounted device (internal and external) shall be identified. Pilot

devices shall utilize collar-type, oversize nameplates provided with the pilot

devices. Non-pilot devices shall have phenolic nameplates, attached using

permanent adhesive. Internal panel devices shall have phenolic identification

plates (hand markings not permitted) and shall be attached using permanent

adhesive. Wiring and terminal blocks

1) LCP/CS/Field instrument master nameplate shall be not less than 1 inch

high with not less than 1/2-inch lettering.

2) External and internal panel devices shall have nameplates not less than 1/2-

inch-high with not less than 3/16-inch lettering.

3) Where field instruments do not permit installation of phenolic nameplates,

provide a round, stamped, stainless steel nameplate using not less than 1/4-

inch-high lettering, neatly fastened by means of stainless-steel wire.

B. Signs:

1. Automatic Equipment and High Voltage Signs:

a. Suitable for exterior use.

b. In accordance with OSHA regulations.

C. Conductor and Cable Markers:

1. Machine printed black characters on white tubing.

2. 10-point type or larger.

D. Conduit and Raceway Markers:

1. 12 GA stainless steel, 3/4-inch by 2-inch minimum.

2. Stamped or engraved lettering.

3. Minimum 1/4-inch high letters.

E. Field Instrument Identification:

1. Refer to Specification 17050-2.02G for Instrument Tags.

F. Equipment Labels:

1. Provide identifying nameplate and nametag on new and reused panels and

equipment as shown in Supplement Signage for Existing Panels and Equipment, or

as listed elsewhere. Enclosure identification shall be located on the enclosure

surface of PLC control panel, motors, pumps, local control stations, instrument

transmitters, analytical controllers, etc.

2. Equipment Nameplates and Nametags: Pumps, valves, gates, and equipment shall

be labeled as follows:

a. Nameplates: Enclosure identification located on the enclosure face with

rectangular screw-on nameplates.

b. Materials: UV resistant, laminated phenolic plastic nameplates with white

background and engraved black enamel filled lettering.

c. Fastening: Secure with self-tapping Type 316 stainless steel screws.




16075 - 6

d. Size: 2 1/4 inch high plate.

e. Test:

1) Descriptive Name: 1 inch high block lettering.

2) Descriptive Tag: 1/2 inch high block lettering.

f. For the same piece of equipment, descriptive nameplate shall be consistently

provided at various locations for all associated equipment with that piece.


A. Nameplates:

1. Provide all nameplates for control panel operator devices (i.e., pushbuttons, selector

switches, pilot lights, etc.):

a. Same material and same color and appearance as the device nameplates, in

order to achieve an aesthetically consistent and coordinated system. All

nameplates shall be UV resistant.

EXECUTION

3.01 INSTALLATION


B. Nameplates:

1. Attach nameplates to equipment with self-tapping stainless-steel screws, approved

waterproof epoxy-based cement or install in metal holders welded to the equipment

as specified for each equipment.

2. Nameplates shall be aligned and level or plumb to within 1/64 inch over the entire

length:

a. Misaligned or crooked nameplates shall be remounted or provide new enclosures

at the discretion of the Engineer.

C. Conductor and Cable Markers:

1. Apply all conductor and cable markers before termination.

2. Non Heat-Shrinkable Tubing:

a. Tubing shall be sized for the wire and insulation on which it is to be placed.

b. Tubing shall be tight on the wire.

c. Characters shall face the open panel and shall read from left to right or top to

bottom.

d. Marker shall start within 1/32 inch of the end of the stripped insulation point.

e. Identification labels shall be installed at each conductor termination.

3. Conductor numbers shall be named based on the equipment tag of the field device

utilizing the electrical power source. The form of the tag shall be 406P1205C2 where

‘406P1205’ represents the equipment designation; ‘C’ indicated a control cable and

2 is a sequential number developed as part of the circuit design. Cable type

designations shall follow the designations listed below:

a. C - Control

b. S - Signal (below 80 volts AC or DC)




16075 - 7

c. P - Power

d. N - Network (Ethernet, Profibus ...)

D. Conduit Markers:

1. Furnish and install conduit markers for every conduit in the electrical system or part

of the process system. Conduits shall be identified as indicated on the

circuit/raceway block diagrams

a. Conduit markings shall match the circuit/raceway block diagrams.

b. For conduits not shown on circuit/raceway block diagrams, provide conduit

markings as described below:

1) Start with a prefix letter that designates its purpose (“C” for control, “P” for

power, “S” for Signal, and “PC” for combined power and control), followed by

a facility code, followed by a sequence number. e.g., C-100P0101 is a control

conduit in the IPS facility for pump 1. P-100P0101 is a power conduit in the

IPS facility for pump 1. S-100P0101 is a signal conduit in the IPS facility for

pump 1. PC-340FV1301 is a combined power and control conduit in PEPS

facility for control valve (Combined circuit allowed per Owner approval only).

2) If the conduit is a continuation or branch of another conduit, the last space is

a letter, such as A,B,C, etc.

3) When a single loop network circuit is utilized among equipment, conduit

number for coming and leaving the equipment shall be assigned a prefix from

and to. e.g. NFR: 100P0101 is a communication network from IPS Facility

Pump 1. NTO: 100P0102 is a communication network to IPS Facility Pump 2.

2. Mark Conduits at the Following Locations:

a. Each end and every 50 feet for conduits greater than 10 feet in length.

b. Where the conduit penetrates a wall or structure.

c. Where the conduit emerges from the ground, slab, etc.

d. The middle of conduits that are 10 feet or less in length.

3. Mark conduits after the conduits have been fully painted.

4. Position conduit markers so that they are easily read from the floor.

5. 12-gauge stainless steel tags 3/4-inch by 2-inch minimum - conduit tags shall be

attached to the raceway with Type 316 stainless steel wires.

6. Mark conduits before construction review by Engineer for punch list purposes.

7. Label intrinsically safe conduits in accordance with the requirements of the National

Electrical Code (NEC).

E. Labeling:

1. Furnish and install permanent warning signs at mechanical equipment that may be

started automatically or from remote locations:

a. Fasten warning signs with round head stainless steel screws or bolts.

b. Locate and mount in a manner to be clearly legible to Operations Personnel.

2. Furnish and install permanent and conspicuous warning signs on equipment (front

and back), doorways to equipment rooms, pull boxes, manholes, and where the

voltage exceeds 600 volts.




16075 - 8

3. Place warning signs on utilization equipment that has more than one source of

power. Use warning signs to identify every panel and circuit number of the

disconnecting means all external power sources:

a. Place warning signs on utilization equipment that has 120 VAC control voltage

sources used for interlocking.

b. Identify panel and circuit number or conductor tag for control voltage source

disconnecting means.

4. Each switch, receptacle and similar device shall include a nameplate indicating the

power source and circuit number providing power to the switch or receptacle. For

circuits other than 120V, identify the voltage and phase (e.g. 277V, 1Ø or 480V, 3Ø).

5. Each panelboard shall be identified with a phenolic nameplate with the black outside

cut to expose white lettering. The nameplate shall include the panel name and tag

number, voltage, phase, ampere rating and power source. Nameplate shall be 2.25

inches high with 1/2-inch-high lettering and attached using self-tapping stainless-

steel screws.

6. Each manhole, handhole or underground pull box lid shall be clearly identified as

“Electric”. In addition, include a 2-inch by 6-inch stainless steel identification tag

utilizing 1/2-inch lettering. The tag shall include the identification number shown on

the drawings, and shall further identify the manhole, handhole or pull box as

“Medium Voltage Power”, “Low Voltage Power”, “Control”, “Signal” or

“Communication”, as applicable.

7. Aboveground pull boxes, junction boxes and terminal boxes shall be identified using a

stainless-steel tag attached to the enclosure using S.S. self-tapping screws. Identify

the box as “Power”, “Control”, “Signal” or “Fiber Optic” as applicable. Assign unique

box numbers in accordance with Owner standards.

8. Each exterior and pole-mounted luminaire shall include a nameplate that includes

information for the lamp type, wattage, voltage rating and power source for the

luminaire. Nameplates shall be readable standing at grade, 2-inch-high with 1/2-

inch-high lettering. Nameplates shall be stainless steel with stamped or engraved

lettering.

9. Provide arc flash labeling in accordance with NEC.

10. Provide labeling indicating short circuit ratings for all power distribution equipment

and control panels in accordance with the NEC and UL requirements.

F. Signs:

1. Automatic Equipment and High Voltage Signs:

a. Mount permanent warning signs at mechanical equipment that may be started

automatically from remote locations. Fasten warning signs with round head

stainless steel screws or bolts. Locate and mount warning signs in a suitable

manner that is acceptable to the ENGINEER.

b. Mount permanent and conspicuous warning signs on the front and back of

equipment, doorways to equipment rooms, pull boxes, and manholes where the

voltage exceeds 600 volts.

c. Place warning signs on equipment that has more than one source of power:

1) Warning sign to identify every power source.

d. Place warning signs on equipment that has a 120 VAC control voltage source

used for interlocking.

2. Provide room signage at Electrical room entrances indicating “Warning-High-Voltage”.




16075 - 9

3. Provide additional signage in accordance with applicable NEC requirements.

4. Provide 20 placard-style signs (7 inch by 10 inch) with warnings to be selected by the

Owner during construction. Placard signs shall be W.H. Brady B-302 style or approved

equal.

G. Equipment Labels:

1. Locate and install on equipment or concrete equipment base.

2. Anchor to equipment or base for easy removal and replacement with ordinary hand

tools.


A. Replace any nameplates, signs, conductor markers, cable markers or raceway labels that

in the sole opinion of the Engineer do not meet the Engineer’s aesthetic requirements.

3.03 SCHEDULES

A. Submit nameplate schedules on 11 by 17-inch sheets.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project 600 Volts or Less Wires and Cables



16123 - 1

SECTION 16123

600 VOLT OR LESS WIRES AND CABLES

GENERAL

1.01 SUMMARY

A. Section Includes Requirements for:

1. 600-volt class wire and cable.

2. Instrumentation class wire and cable.

3. Network cable.

B. Related Sections






1.02 REFERENCES


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

1. B 3 - Standard Specification for Soft or Annealed Copper Wire.

2. B 8 - Specification for Concentric-Lay–Stranded Copper Conductors, Hard, Medium-

Hard, or Soft.

3. A167 - Standard Specification for Stainless and Heat Resisting Chromium-Nickel

Steel Plate, Sheet, and Strip.

4. B263 - Standard Test Method for Determination of Cross-Sectional Area of Stranded

Conductors.

C. Insulated Cable Engineers Association (ICEA):

1. IPCEA S-61-402 for thermoplastic insulated wire and cable for the transmission and

distribution of electrical energy.

2. IPCEA S-61-402 for rubber insulated wire and cable for the transmission and

distribution of electrical energy.

3. T-29-520 - Conducting Vertical Cable Tray Flame Tests and a Theoretical Heat Input

of 210,000 Btu/hour.

4. S-58-679 - Standard for Control Cable Conductor Identification.

D. National Fire Protection Association (NFPA):

1. Article 70 - National Electrical Code (NEC).

2. Article 72 - National Fire Alarm Code.

3. Article 101 - Life Safety Code.

4. Article 262 - Standard Method of Test for Flame Travel and Smoke of Wires and

Cables for Use in Air-Handling Spaces.




16123 - 2

E. Federal Specification J-C 30A.

F. Underwriter's Laboratories Inc., (UL):

1. UL 1277 Subject - Electrical Power and Control Tray Cables with Optional Optical-fiber

Members.

2. UL 1063 - Machine-Tool Wires and Cables.

3. UL 1581 - Reference Standard for Electrical Wires, Cables, and Flexible Cords.

4. UL-2196 - Tests for Fire Resistive Cables.

5. UL-1424 - Cables for Power-Limited Fire-Alarm Circuits.

6. UL-1569 - Metal-Clad Cables.

7. UL-2225 - Metal-Clad Cables and Cable-Sealing Fittings For Use in Hazardous

(Classified) Locations.

8. 13 - Standard for Safety Power-Limited Circuit Cables.

9. 44 - Standard for Safety Thermoset - Insulated Wires and Cables.

10. 62 - Standard for Safety Flexible Cord and Fixture Wire.

11. 486A - Standard for Safety; Wire Connectors and Soldering Lugs for Use with Copper

Conductors.

12. 486C - Splicing Wire Connectors.

13. 510 - Standard for Safety Polyvinyl Chloride, Polyethylene, and Rubber Insulating

Tape.

14. 854 - Standard for Safety Service-Entrance Cables.

G. Institute of Electrical and Electronics Engineers, Inc. (IEEE):

1. 48 - Standard Test Procedures and Requirements for Alternating-Current Cable

Terminations.

H. National Electrical Manufacturers’ Association (NEMA):

1. CC 1 - Electric Power Connectors for Substations.

2. WC 55 - Instrumentation Cables and Thermocouple Wire.

3. WC 70 - Standard for Nonshielded Power Cables Rated 2,000 Volts or Less for the

Distribution of Electrical Energy.

1.03 DEFINITIONS


B. Definitions of terms and other electrical considerations as set forth in the:

1. Insulated Cable Engineering Association (ICEA).

2. American Society of Testing Materials (ASTM)


A. Furnish and install the complete wire and cable system.




16123 - 3

1.05 SUBMITTALS

A. Furnish submittals in accordance with Sections 01330 and 16050.

B. Product Data:

1. Manufacturer of Wire and Cable.

2. Insulation:

a. Type.

b. Voltage class.

3. American Wire Gauge size.

4. Conductor material.

5. Pulling compounds.

C. Shop Drawings:

1. Show splice locations.

a. For each proposed splice location, provide written justification describing why the

splice is necessary. Splices are not allowed unless approved by the Engineer.

D. Test Reports:

1. Submit test reports for meg-ohm tests.

E. Calculations:

1. Submit cable pulling calculations for all cables larger than 2/0 AWG and pulling

lengths longer than 200 feet.

2. Submit cable pulling calculations for all conductor sizes for pulling lengths longer

than 500 feet.

3. Submit the calculations to the ENGINEER a minimum of 2 weeks before the cable

pull.

1.06 CABLE TESTING AND REPLACEMENT

A. All cables that fail to meet NETA standards shall be replaced at the discretion of the

Engineer and Owner.

B. All wires and cables shall be tested individually.

C. All tests shall conform to NETA standards.



B. All wires and cables shall be UL listed and labeled.






16123 - 4

1.09 WARRANTY




PRODUCTS

2.01 MANUFACTURERS

A. One of the Following or Equal:

1. 600 Volt Class Wire and Cable:

a. General Cable.

b. Okonite Company.

c. Southwire Company.

2. Instrumentation Class Wire and Cable:

a. Alpha Wire Company.

b. Belden CDT.

c. General Cable BICC Brand.

d. Okonite Company.

e. Rockbestos Surprenant Cable Corporation.

3. Network Cables:

a. Belden CDT.

b. Siemens.

c. Lucent.

2.02 MATERIALS

A. Conductors:

1. Copper per ASTM B 3.

2. Minimum 97 percent conductivity.


A. General:

1. Conductors, include grounding conductors, shall be stranded copper. Solid

conductors shall not be permitted. Aluminum conductor wire and cable will not be

permitted.

2. Provide new wires and cables manufactured within 1 year of the date of delivery to

the site.

3. Permanently mark each wire and cable with the following at 24 inch intervals:

a. American Wire Gauge (AWG) size.

b. Voltage rating.

c. Insulation type.




16123 - 5

d. UL symbol.

e. Month and year of manufacture.

f. Manufacturer's name.

4. Identify and mark wire and cable as specified in Section 16075:

a. Use integral color insulation for Number 2 AWG and smaller wire.

b. Wrap colored tape around cable larger than Number 2 AWG.

B. 600 Volt Class Wire and Cable:

1. Provide American Wire Gauge (AWG) or kcmil sizes as indicated on the Drawings:

a. When not indicated on the Drawings, size wire as follows:

1) In accordance with the National Electrical Code:

a) Use 75-degree Celsius ampacity ratings.

b) Ampacity rating after all derating factors, equal to or greater then rating

of the overcurrent device.

2) Provide Number 12 AWG minimum for power conductors.

3) Provide Number 14 AWG minimum for control conductors.

b. Provide tin plated copper ground wire to be used on aluminum cable tray.

2. Provide Class B stranding per ASTM B 8:

a. Provide Class C stranding where extra flexibility is required.

3. Insulation:

a. XHHW-2.

b. 90-degree Celsius rating in wet or dry locations.

4. Conductors for feeders shall be sized to prevent a voltage drop exceeding 3 percent

at the farthest outlet of power, heating, and lighting loads, or combinations of such

loads, and where the maximum total voltage drop on both feeders and branch

circuits to farthest connected load does not exceed 5 percent.

5. Multi-conductor Cables:

a. Type 1 – Multi-conductor Control Cable:

1) Conductors:

a) No. 14 AWG, seven -strand copper, tray cable rated.

b) Insulation: 30-mil PVC.

c) UL 1581 listed as Type XHHW-2 rated VW-1.

d) Conductor group bound with spiral wrap of barrier type.

e) Color Code: In accordance with ICEA S-58-679, Method 1, Table 2.

2) Cable: Passes the ICEA T-29-520 210,000 Btu per hour Vertical Tray Flame

Test.

3) Cable Sizes:

No. of Conductors Max. Outside Diameter (Inches) Jacket Thickness (Mils)

3 0.41 45

5 0.50 45

6 0.53 45

9 0.64 60

12 0.72 60




16123 - 6

No. of Conductors Max. Outside Diameter (Inches) Jacket Thickness (Mils)

19 0.83 60

25 1.00 60

37 1.15 80

b. Type 2, Multi-conductor Power Cable:

1) Conductors:

a) Class B stranded, coated copper.

b) Insulation: Chemically cross-linked ethylene-propylene with Hypalon

jacket.

c) UL 1581 listed as Type EPR, rated VW-1.

d) Color Code:

(1) Conductors, size No. 8 AWG and smaller, colored conductors, ICEA S-

58-679, Method 1, Table 1.

(2) Conductors, size No. 6 AWG and larger, ICEA S-58-679, Method Y.

2) Cable pass the ICEA T-29-520 210,000 Btu/hr Vertical Tray Flame Test.

3) Cable Sizes:

Conductor

Size

Minimum Ground

Wire Size

No. of Conductors

(not including

ground)

Max Outside

Diameter

(Inches)

Nominal Jacket

Thickness

(Mils)

12 12 2 0.42 45

3 0.45 45

4 0.49 45

10 10 2 0.54 60

3 0.58 60

4 0.63 60

8 10 2 0.62 60

3 0.66 60

4 0.72 60

6 8 3 0.74 60

4 0.81 60

4 6 3 0.88 60

4 0.97 80

2 6 3 1.01 80

4 1.11 80

1/0 6 3 1.22 80

4 1.35 80

2/0 4 3 1.32 80

4 1.46 80

4/0 4 3 1.56 80

4 1.78 110




16123 - 7

6. Instrumentation Cables:

a. Type 3, No. 18 AWG, Twisted, Shielded Pair, Instrumentation Cable: Single pair,

designed for noise rejection for process control, computer, or data log application

is meeting NEMA WC 55 requirements.

1) Outer Jacket: 45-mil nominal thickness.

2) Individual Pair Shield: 1.35-mil, double-faced aluminum/synthetic polymer

overlapped to provide 100 percent coverage.

3) Dimension: 0.31-inch nominal OD.

4) Conductors:

a) Bare soft annealed copper, Class B, seven-strand concentric, meeting

requirements of ASTM B8.

b) 20 AWG, seven-strand tinned copper drain wire.

c) Insulation: 15-mil nominal PVC.

d) Jacket: 4-mil nominal nylon.

e) Color Code: Pair conductors black and white.

b. Type 4, No. 18 AWG, Twisted, Shielded Triad Instrumentation Cable: Single triad,

design for noise rejection for process control, computer, or data log applications

meeting NEMA WC 55 requirements.

1) Outer Jacket: 45-min nominal.

2) Individual Pair Shield: 1.35-mil, double-faced aluminum/synthetic polymer,

overlapped to provide 100 percent coverage.

3) Dimension: 0.32-inch nominal OD.

4) Conductors:

a) Bare soft annealed copper, Class B, seven-strand concentric, meeting

requirements of ASTM B8.

b) 20 AWG, seven-strand, tinned copper drain wire.

c) Insulation: 15-mil nominal PVC.

d) Jacket: 4-mil nylon.

e) Color Code: Triad conductors black, red, and white.

c. Type 5, No. 18 AWG, Multi-Twisted, Shielded Pairs with a Common, Overall Shield

Instrumentation Cable: Designed for use as instrumentation, process control, and

computer cable, meeting NEMA WC 55 requirements.

1) Conductors:

a) Bare soft annealed copper, Class B, seven-strand concentric, in

Accordance with ASTM B8.

b) Tinned copper drain wires.

c) Pair drain wire size AWG 20, group drain wire size AWG 18.

d) Insulation: 15-mil PVC.

e) Jacket: 4-mil nylon.

f) Color Code: Pair conductors black and red with red conductor numerically

printed for group identification.

g) Individual Pair Shield: 1.35-mil, double-faced aluminum/synthetic

polymer.




16123 - 8

2) Cable Shield: 2.35-mil, double-faced aluminum/synthetic polymer,

overlapped for 100 percent coverage.

3) Cable Sizes:

Number of Pairs Max. Outside Diameter (Inches) Nominal Jacket Thickness (Mils)

4 0.50 45

8 0.68 60

12 0.82 60

16 0.95 80

24 1.16 80

36 1.33 80

50 1.56 80

7. VFD Cables:

a. Type 6 - Flexible, shielded VFD cable with single ground conductor

1) UL 2277, 1000V flexible motor supply cable.

2) TC-ER rated, 90 degrees C wet or dry.

3) Conductors:

a) 12 AWG thru 10 AWG, tinned copper per ASTM B33, Class K stranding

per ASTM B172.

b) 8 AWG thru 2 AWG, tinned copper per ASTM B33, Class H stranding per

ASTM B173.

c) Insulation: 45-mil XLPE for conductors 12 AWG thru 10 AWG; 60-mil

XLPE for conductors 8 AWG thru 2 AWG.

d) One full-sized green/yellow insulated ground conductor, same AWG size

as circuit conductors.

4) Cable Shield: Overall aluminum shield with minimum 25% overlap with

overall tinned copper braid with 85% coverage and full sized tinned copper

drain wire(s).

5) Jacket: UV-sunlight resistant, flame retardant and chemical resistant.

6) Cable Sizes:

Conductor

Size

Minimum Ground

Wire Size

No. of Conductors

(not including

ground)

Max Outside

Diameter

(Inches)

Nominal Jacket

Thickness

(Mils)

12 12 3 0.70 60

10 10 3 0.74 60

8 8 3 0.94 80

6 6 3 1.03 80

4 4 3 1.17 80

2 2 3 1.33 80

C. Network Cables:

a. Type 11, Shielded Category 6 (CAT 6)

b. Conductors:

1) 24 AWG solid bare copper conductors.

2) Shielded cable with shielded connectors.




16123 - 9

3) Provide strain relief on connectors.

c. Insulation:

1) Polyolefin.

2) 4 non-bonded twisted pair cables formed into a cable core.

d. Color Code:

1) Pair 1: White/Blue Stripe and Blue

2) Pair 2: White/Orange Stripe and Orange

3) Pair 3: White/Green Stripe and Green

4) Pair 4: White/Brown Stripe and Brown

e. Outer Jacket:

1) PVC with ripcord.

2) Color red.

f. Electrical Characteristics:

1) Frequency Range: 0.772-100 MHz.

2) Attenuation: 32.1dB/100m.

3) Near-End Crosstalk (NEXT): 39.3 dB.

4) Power Sum NEXT: 37.3 dB.

5) Attenuation to Crosstalk Ratio: 7.2 dB.

6) Power Sum Attenuation to Crosstalk Ratio: 5.3 dB/100m.

7) Equal Level Far-End Crosstalk (ELFEXT): 22.8 dB.

8) Power-Sum ELFEXT: 19.8 dB/100m.

9) Return Loss: 17.3 dB.

10) Propagation Delay: 537 ns/100m.

11) Delay Skew: 45 ns/100m.

12) Propagation Delay (Skew), max: 2.5 ns/100m

g. Terminate CAT 6 cables in an 8P8C T568B fashion.

2. Type 12: RS-485:

a. Two-wire:

1) Shielded twisted pair.

2) Tinned, copper conductors minimum with 7 by 30 stranding.

3) AWG #22.

4) Insulation:

a) FHDPE: Foam high-density polyethylene.

b) 300-volt insulation level.

5) Outer shield:

a) 100 percent coverage.

b) Tape/braid.

c) Aluminum foil-polyester tape.

d) Tinned copper braid.

6) Outer shield drain wire:

a) Tinned, copper conductor minimum with 7 by 30 stranding.

b) AWG #22.

mailto:537@100Mhz




16123 - 10

7) Outer jacket PVC:

a) Sunlight resistant.

8) UL/CSA flame tested.

9) Minimum bending radius 2.5 inches.

10) Nominal OD 0.284 inch]

2.04 ACCESSORIES

A. Tape:

1. General Purpose, Flame Retardant: 7-mil, vinyl plastic, Scotch Brand 33, rated for 90

degrees C minimum, meeting requirements of UL 510.

2. Flame Retardant, Cold and Weather Resistant: 8.5-mil, vinyl plastic, Scotch Brand 88.

B. Connectors and Terminations:

1. Nylon, Self-Insulated Crimp Connectors:

a. Manufacturers and Products:

1) Thomas & Betts; Sta-Kon.

2) Burndy; Insulug.

3) ILSCO.

2. Nylon, Self-Insulated, Crimp Locking-Fork, Torque-Type Terminator:

a. Manufacturers and Products:


2) Burndy; Insulug.

3) ILSCO.

3. Self-Insulated, Set Screw Wire Connector:

a. Two piece compression type with setscrew in brass barrel.

b. Insulated by insulator cap screwed over brass barrel.

c. Manufacturer: 3M Co.

C. Cable Lugs:

1. In accordance with NEMA CC 1.

2. Rated 600 volts of same material as conductor metal.

3. Insulated, Locking-Fork, Compression Lugs:

a. Suitable for use with 75 degrees C wire at full NFPA 70, 75 degrees C ampacity.

b. Seamless.

c. Manufacturers and Products:


2) ILSCO; ILSCONS.




16123 - 11

4. Uninsulated Crimp Connectors and Terminators:


b. Manufacturers and Products:

1) Thomas & Betts; Color-Keyed.

2) Burndy, Hydent.

3) ILSCO.

5. Uninsulated, Bolted, Two-Way Connectors and Terminators:


b. Manufacturers and Products:

1) Thomas & Betts; Locktite.

2) Burndy; Quiklug.

3) ILSCO.

D. Cable Ties:

1. Nylon, adjustable, self-locking, and reusable.

2. Manufacturer and Product: Thomas & Betts: TY-RAP.

3. Cable ties installed outdoors shall be UV resistant and rated for use in direct sunlight.

E. Heat Shrinkable Insulation:

1. Thermally stabilized, cross-linked polyolefin.

2. Manufacturer and Product: Thomas & Betts; SHRINK-KON.

F. Pulling Compound:

1. Nontoxic, noncorrosive, noncombustible, nonflammable, wax-based lubricant; UL

listed.

2. Suitable for rubber, neoprene, PVC, polyethylene, hypalon, CPE, and lead-covered

wire and cable.

3. Suitable for zinc-coated steel, aluminum, PVC, bituminized fiber, and fiberglass

raceways.

4. Manufacturers and Products:

a. Polywater, Inc.

b. Cable Grip Co.


A. Assembly and testing of cable shall comply with the applicable requirement of ICEA

Publication No. S-68-516.

B. Test in accordance with the requirements of UL 44 and 854 Standards.




16123 - 12

EXECUTION

3.01 INSTALLATION


B. Color Coding:

1. Color coding shall be consistent throughout the facility.

2. The following color code shall be followed for all 240/120 Volt and 208/120 Volt

systems:

a. Phase A - black.

b. Phase B - red.

c. Phase C - blue.

d. Single Phase System - black for one hot leg, red for the other.

e. Neutral - white.

f. High Phase or Wild Leg - orange.

g. Equipment Ground - green.

3. The following color code shall be followed for all 480/277 Volt systems:

a. Phase A - brown.

b. Phase B - orange.

c. Phase C - yellow.

d. Neutral - gray.

e. Equipment Ground - green.

4. The following color code shall be followed for all 120 VAC control wiring:

a. Power - red.

b. Neutral - white.

5. The following color code shall be followed for all general purpose DC control circuits:

a. Negative – white/blue stripe.

b. Positive - blue.

6. The following color code shall be followed for all signal (4-20mA or 1-5VDC) circuits:

a. Negative - black.

b. Positive - white.

7. Switch legs shall be violet. 3-way switch runners shall be pink.

8. Wires in intrinsically safe circuits shall be light blue.

9. Wire colors shall be implemented in the following methods:

a. Wires manufactured of the desired color.

b. Continuously spiral wrap the first 6 inches of the wire from the termination point

with colored tape:

1) Colored tape shall be wrapped to overlap 1/2 of the width of the tape.




16123 - 13

C. Install conductors only after the conduit installation is complete, and all enclosures have

been vacuumed clean, and the affected conduits have been swabbed clean and dry:

1. Install wires only in approved raceways.

2. Do not Install wire:

a. In incomplete conduit runs.

b. Until after the concrete work and plastering is completed.

D. Properly coat wires and cables with pulling compound before pulling into conduits and

prevent mechanical damage to conductors during installation:

1. For all Number 4 AWG and larger, use an approved wire-pulling lubricant while cable

is being installed in conduit:

a. Ideal Products.

b. Polywater Products.

c. 3M Products.

d. Greenlee Products.

e. Or equal as recommended by cable manufacturer.

f. Do not use oil, grease or similar substances.

E. Cable Pulling:

1. For cables Number 1 AWG and smaller, install cables by hand.

2. For cables larger than Number 1 AWG, power pulling winches may be used if they

have cable tension monitoring equipment.

3. Provide documentation that maximum cable pulling tension was no more than 75

percent of the maximum recommended level as published by the cable

manufacturer. If exceeded, the ENGINEER may, at his discretion, require replacement

of the cable.

4. Ensure cable pulling crews have all calculations and cable pulling limitations while

pulling cable.

5. Make splices or add a junction box or pullbox where required to prevent cable pulling

tension or sidewall pressure from exceeding 75 percent of manufacturer’s

recommendation for the specified cable size:

a. Make splices in manholes or pull boxes only.

b. Leave sufficient slack to make proper connections.

F. Use smooth-rolling sheaves and rollers when pulling cable into cable tray to keep pulling

tension and bending radius within manufacturer’s recommendations.

G. Install and terminate all wire in accordance with manufacturer's recommendations.

H. Neatly arrange and lace conductors in all switchboards, panelboards, pull boxes, and

terminal cabinets by means of wire ties:

1. Do not lace wires in gutter or panel channel.

2. Install all wire ties with a flush cutting wire tie installation tool:

a. Use a tool with an adjustable tension setting.

3. Do not leave sharp edges on wire ties.




16123 - 14

I. Terminate solid conductors at equipment terminal screws with the conductor tightly

wound around the screw so that it does not protrude beyond the screw head:

1. Wrap the conductor clockwise so that the wire loop is closed as the loop is tightened.

2. Do not use crimp lugs on solid wire.

J. Terminate stranded conductors on equipment box lugs such that all conductor strands

are confined within the lug:

1. Use ring type lugs if box lugs are not available on the equipment.

K. Splices:

1. Provide continuous circuits from origin to termination whenever possible.

a. Obtain ENGINEER’s approval prior to making any splices.

2. Where splices are necessary because of extremely long wire or cable lengths that

exceed standard manufactured lengths:

a. Refer to Section 16050 for box NEMA rating requirements.

b. Make splices in labeled junction boxes for power conductors.

c. Make splices for control and instrument conductors in terminal boxes:

1) Provide terminal blocks.

2) Terminate all conductors on terminal blocks with wire ferrules.

3. Splices not permitted for power and control conductors.

4. If splices have been approved by the ENGINEER, clearly label junction and terminal

boxes containing splices with the word "SPLICE." Provide this label on approved

power, control, and signal junction and terminal boxes.

5. Leave sufficient slack at junction boxes and termination boxes to make proper

splices and connections. Do not pull splices into conduits.

6. Install splices with compression type butt splices and insulate using a heat-shrink

sleeve:

a. In NEMA 4 or NEMA 4X areas, provide heat-shrink sleeves that are listed for

submersible applications.

7. Splices in below grade pull boxes, in any box subject to flooding, and in wet areas

shall be made waterproof using:

8. A heat shrink insulating system listed for submersible applications.

9. An epoxy resin splicing kit.

3.02 OTHER APPROVED DIRECT BURIAL SPLICE KIT.

A. Apply circuit and wire markers to all wires as described below:

1. Circuit Identification Location: Identify power, instrumentation, and control conductor

circuits, using circuit name as described below, at each termination and in accessible

locations such as manholes, hand-holes, panels, switchboards, motor control

centers, pull boxes, and terminal boxes.

2. Circuit Name:

a. Assign circuit name based on device or equipment at load end of circuit as

indicated on the Drawings and as described in Section 17050 article 3.01.

b. Where this would result in same name being assigned to more than one circuit,

add number or letter to each otherwise identical circuit name to make it unique.




16123 - 15

3. Method:

a. Conductors No. 3 AWG and Smaller: Identify with sleeves or heat bond markers.

b. Taped-on markers or tags relying on adhesives not permitted.

c. Cables and Conductors No. 2 and Larger:

1) Identify with marker plates; or

2) Tie-on cable marker tags.

3) Attach with nylon tie cord.

B. Instrumentation Class Cable:

1. Install instrumentation class cables in separate raceway systems from power cables:

a. Install instrument cable in metallic conduit within non-dedicated manholes or pull

boxes.

b. Install cable without splices between instruments or between field devices and

instrument enclosures or panels.

2. Do not make intermediate terminations, except in designated terminal boxes as


3. Refer to Section 16050 for shield grounding requirements.

C. Signal Cable:

1. Separate and isolate electrical signal cables from sources of electrical noise and

power cables by minimum 12 inches.

D. Submersible cable in wet wells:

1. Provide Kellem’s grip or stainless steel wire mesh to support cable weight and avoid

stress on insulation.

E. Wiring Allowances:

1. Equipment locations may vary slightly from the drawings. Include an allowance for

necessary conductors and terminations for motorized equipment, electrical outlets,

fixtures, communication outlets, instruments, and devices within 10 linear feet of

locations indicated on the Drawings.

2. Locations for pull boxes, manholes, and direct buried raceway trenches may vary

slightly from the drawings. Include an allowance for necessary conductors and

related materials to provide conductors to all pull boxes, manholes and direct buried

raceway trenches within 20 linear feet of locations indicated on the Drawings.



B. Grounding:

1. Refer to Section 16060.

3.04 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Conduits



16130 - 1

SECTION 16130

CONDUITS

GENERAL

1.01 SUMMARY


1. Metallic conduits.

2. Nonmetallic conduits.

3. Conduit bodies.

4. Conduit fittings and accessories.

5. Conduit installation.


1. The Contract Documents are complementary; what is called for by one is as binding as if

called for by all.


subcontractors, suppliers, and other individuals or entities performing or furnishing any of

Contractor’s Work.

3. The following sections are related to the Work described in this Section. This list of related

sections is provided for convenience only and is not intended to excuse or otherwise diminish

the duty of the Contractor to see that the completed Work complies accurately with the

Contract Documents.



c. Section 16070 - Hangers and Supports.

d. Section 16133 – Direct Buried Raceway Trench System.

e. Section 16075 - Electrical Identification.

1.02 REFERENCES


B. American National Standards Institute (ANSI):

1. C80.1 - Electrical Rigid Steel Conduit.

2. C80.3 - Steel Electrical Metallic Tubing.

3. C80.5 - Electrical Rigid Aluminum Conduit.

4. C80.6 - Electrical Intermediate Metal Conduit.

C. National Electrical Manufacturer’s Association (NEMA):

1. RN-1 - Polyvinyl Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and

Intermediate Steel Conduit.

2. TC2 - Electrical Polyvinyl Chloride (PVC) Conduit.

3. TC3 - Polyvinyl Chloride (PVC) Fittings for Use with Rigid PVC Conduit and Tubing.

4. TC7 - Smooth-Wall Coilable Electrical Polyethylene Conduit.




16130 - 2

5. TC13 - Electrical Nonmetallic Tubing.

6. TC14 - Reinforced Thermosetting Resin Conduit (RTRC) and Fittings.

D. Underwriters Laboratories (UL):

1. 1 - Standard for Flexible Metal Conduit.

2. 6 - Standard for Electrical Rigid Metal Conduit - Steel.

3. 6A - Standard for Electrical Rigid Metal Conduit - Aluminum, Red Brass, and Stainless Steel.

4. 360 - Standard for Liquid-Tight Flexible Steel Conduit.

5. 651 - Standard for Schedule 40 and 80 Rigid PVC Conduit and Fittings.

6. 651B - Standard for Continuous Length HDPE Conduit.

7. 797 - Standard for Electrical Metallic Tubing - Steel.

8. 1242 - Standard for Electrical Intermediate Metal Conduit - Steel.

9. 1653 - Standard for Electrical Nonmetallic Tubing.

10. 1660 - Standard for Liquid-Tight Flexible Nonmetallic Conduit.

11. 1684 - Standard for Reinforced Thermosetting Resin Conduit (RTRC) and Fittings.

1.03 DEFINITIONS


B. Specific definitions and abbreviations:

1. Conduit bodies: A separate portion of a conduit system that provides access through a

removable cover to the interior of the system at a junction of 2 or more conduit sections.

Includes, but not limited to: shapes C, E, LB, T, X, etc.

2. Conduit fitting: An accessory that serves primarily a mechanical purpose. Includes, but not

limited to: bushings, locknuts, hubs, couplings, reducers, etc.

3. GRC: Galvanized rigid steel conduit.

4. PCS: PVC coated rigid steel conduit.

5. PVC: Polyvinyl chloride rigid nonmetallic conduit.

6. SLT: Seal-tight – liquid-tight flexible conduit.

7. FLX: Flexible metallic conduit.

8. NPT: National pipe thread.


A. Provide conduits, conduit bodies, fittings, junction boxes and all necessary components, whether

or not indicated on the Drawings, as required, to install a complete electrical raceway system.

1.05 SUBMITTALS


B. Product data:

1. Furnish complete manufacturer’s catalog sheets for every type and size of conduit, fitting,

conduit body, and accessories to be used on the Project.

2. Furnish complete manufacturer’s recommended special tools to be used for installation if

required.




16130 - 3

C. Certifications:

1. Furnish PVC-coated conduit manufacturer’s certification for each installer.

D. Record Documents:

1. Incorporate all changes in conduit routing on electrical plan drawings.

2. Dimension underground and concealed conduits from building lines.

3. Furnish hard copy drawings and electronic files in AutoCAD format Version: 2018 or later.

E. Installation drawings: Installation drawings, including individual conduit numbers, routing, sizes,

cable sizes, and circuit numbers for each conduit.



B. All conduits, conduit bodies, and fittings shall be UL listed and labeled.

C. Every installer of PCA or PCS conduits shall be certified by the manufacturer for installation of the

conduit.



B. Do not expose type PVC, FRD, NFC and ENT to direct sunlight.

C. Do not store conduit in direct contact with the ground.



1.09 SEQUENCING

A. Before installing any conduit or locating any device box:

1. Examine the complete set of Drawings and Specifications, and all applicable shop drawings.

2. Verify all dimensions and space requirements and make any minor adjustments to the

conduit system as required to avoid conflicts with the building structure, other equipment, or

the work of other trades.

1.10 WARRANTY







16130 - 4

PRODUCTS

2.01 MANUFACTURERS

A. Galvanized rigid steel conduit:


a. Western Tube and Conduit.

b. Allied Tube and Conduit.

c. Wheatland Tube Co.

B. Polyvinyl chloride coated rigid steel conduit:


a. Robroy Industries.

b. Ocal, Inc.

C. Flexible metallic conduit:


a. AFC Cable Systems.

b. Southwire.

c. Electri-flex Company.

D. Seal-tight liquid-tight flexible conduit:


a. Southwire.

b. AFC Cable Systems.

c. Electri-flex.

d. Anaconda.

E. Rigid nonmetallic polyvinyl chloride conduit:


a. Carlon.

b. Cantex.

c. Triangle Conduit and Cable.

F. Inner duct:


a. Carlon.

b. Endot Industries.

c. MaxCell.

G. Conduit bodies:


a. Crouse-Hinds.

b. Appleton.

c. O-Z / Gedney.




16130 - 5

d. Ocal.

e. Robroy.

f. Carlon.

H. Galvanized rigid steel conduit expansion fittings:


a. Crouse-Hinds.

b. Appleton.

c. O-Z / Gedney.

I. Conduit sleeve:


a. Crouse-Hinds.

b. Appleton.

c. O-Z / Gedney.

J. Conduit seals:


a. Appleton.

b. Crouse-Hinds.

c. O-Z / Gedney.

K. Conduit hangers and supports:


L. Conduit through wall and floor seals:

1. The following or equal:

a. O-Z/Gedney:

1) Type "WSK".

2) Type “CSM”.

2.02 COMPONENTS

A. GRC:

1. All threads: NPT standard conduit threads with a 3/4-inch taper per foot:

a. Running conduit threads are not acceptable.

2. Hot-dip galvanized inside and out:

a. Ensures complete coverage and heats the zinc and steel to a temperature that ensures

the zinc alloys with the steel over the entire surface.

b. Electro-galvanizing is not acceptable.

3. Manufactured in accordance with:

a. UL-6.

b. ANSI C80.1.




16130 - 6

B. PCS:

1. The steel conduit, before PVC coating, shall be new, unused, hot-dip galvanized material,

conforming to the requirements for type GRC.

2. Coated conduit NEMA Standard RN-1:

a. The galvanized coating may not be disturbed or reduced in thickness during the cleaning

and preparatory process.

3. Factory bonded PVC jacket:

a. The exterior galvanized surfaces shall be coated with primer before PVC coating to

ensure a bond between the zinc substrate and the PVC coating.

b. Nominal thickness of the exterior PVC coating shall be 0.040 inch except where part

configuration or application of the piece dictate otherwise.

c. PVC coating on conduit and associated fittings shall have no sags, blisters, lumps, or

other surface defects and free of holes and holidays.

d. The PVC adhesive bond on conduit and fittings shall be greater than the tensile strength

of the PVC plastic coating:

1) Confirm bond with certified test results.

4. A urethane coating shall be uniformly and consistently applied to the interior of all conduit

and fittings:

a. Nominal thickness of 0.002 inch.

b. Conduit having areas with thin or no coating are not acceptable.

c. All threads shall be coated with urethane.

5. The PVC exterior and urethane interior coatings applied to the conduit shall afford sufficient

flexibility to permit field bending without cracking or flaking at temperature above

30 degrees Fahrenheit (-1 degree Celsius).

6. PCS conduit bodies and fittings:

a. Malleable iron.

b. The conduit body, before PVC coating, shall be new, unused material and shall conform

to appropriate UL standards.

c. The PVC coating on the outside of conduit bodies shall be 0.040 inch thick and have a

series of longitudinal ribs to protect the coating from tool damage during installation.

d. 0.002 inch interior urethane coating.

e. Utilize the PVC coating as an integral part of the gasket design.

f. Stainless steel cover screws heads shall be encapsulated with plastic to assure corrosion

protection.

g. A PVC sleeve extending 1 conduit diameter or 2 inches, whichever is less, shall be

formed at each female conduit opening.

1) The inside diameter of the sleeve shall be the same as the outside diameter of the

conduit to be used.

2) The sleeve shall provide a vapor and moisture tight seal at every connection.

C. FLX:

1. Materials:

a. Single strip aluminum alloy.

b. Single strip steel hot-dip galvanized on all 4 sides before conduit fabrication.

2. Interlocking design formed from continuous metal strip for integrity and flexibility.




16130 - 7

3. Manufactured in accordance with:

a. UL-1.

D. SLT:

1. Temperature rated for use in the ambient temperature at the installed location but not less

than the following:

a. General purpose:

1) Temperature range -20 degrees Celsius to +80 degrees Celsius.

b. Oil resistant:

1) Temperature range -20 degrees Celsius to +60 degrees Celsius.

2. Sunlight resistant, weatherproof, and watertight.

3. Manufactured from single strip steel, hot-dip galvanized on all 4 sides before conduit

fabrication.

4. Strip steel spiral wound resulting in an interior that is smooth and clean for easy wire pulling.

5. Overall polyvinyl chloride jacket.

6. With integral copper ground wire, built in the core, in conduit trade sizes 1/2 inch through 1-

1/4 inch.

E. PVC:

1. Extruded from virgin polyvinyl chloride compound:

a. Schedule 40 unless otherwise specified.

b. Schedule 80 extra heavy wall where specified.

2. Rated for 90 degrees Celsius conductors or cable.

3. Rated for use in direct sunlight. Conduit bodies:

F. Conduit bodies:

1. Material consistent with conduit type:

a. Malleable iron bodies and covers when used with type GRC conduit.

b. PVC bodies and covers when used with type PVC.

c. PVC-coated malleable iron bodies and covers when used with type PCS.

d. PVC-coated copper-free cast aluminum bodies and covers when used with Malleable iron

or aluminum bodies with pressed steel.

2. Conduit bodies to conform to Form 8, Mark 9, or Mogul design:

a. Mogul design conforming to NEC requirements for bending space for large conductors for

conduit trade sizes of 1 inch and larger with conductors #4 AWG and larger, or where

required for wire bending space.

3. Gasketed covers attached to bodies with stainless steel screws secured to threaded holes in

conduit body.




16130 - 8

2.03 ACCESSORIES

A. Connectors and fittings:

1. Manufactured with compatible materials to the corresponding conduit.

B. Insulated throat metallic bushings:

1. Construction:

a. Malleable iron or zinc plated steel when used with steel conduit.

b. Aluminum when used with aluminum conduit.

c. Positive metallic conduit end stop.

d. Integrally molded non-combustible phenolic insulated surfaces rated

150 degrees Celsius.

e. Use fully insulated bushings on nonmetallic conduit system made of high impact

150 degrees Celsius rated non-combustible thermosetting phenolic.

C. Insulated grounding bushings:

1. Construction:

a. Malleable iron or steel, zinc plated, with a positive metallic end stop.

b. Integrally molded non-combustible phenolic insulated surfaces rated

150 degrees Celsius.

c. Tin plated copper grounding saddle for use with copper or aluminum conductors.

D. Electrical unions (Erickson Couplings):

1. Construction:

a. Malleable iron for use with steel conduit.

b. Aluminum for use with aluminum conduit.

c. Concrete tight, 3-piece construction.

d. Rated for Class I Division 1 Group D in hazardous areas.

E. FLX fittings:

1. Provide insulated die-cast connectors with ridges that thread into the inside of the conduit to

achieve a force fit.

2. Binding screw connectors are not acceptable.

F. SLT fittings:

1. Construction:

a. Malleable iron.

b. Furnished with locknut and sealing ring.

c. Liquid-tight, rain-tight, oil-tight.

d. Insulated throat.

e. Furnish as straight, 45-degree elbows and 90-degree elbows.

f. Designed to prevent sleeving:

1) Verify complete bonding of the raceway jacket to the plastic gasket seal.




16130 - 9

g. Equipped with grounding device to provide ground continuity irrespective of raceway core

construction. Grounding device, if inserted into raceway and directly in contact with

conductors, shall have rolled over edges for sizes under 5 inches.

h. Where terminated into a thread less opening using a threaded hub fitting, a suitable

moisture resistant/oil resistant synthetic rubber gasket shall be provided between the

outside of the box or enclosure and the fitting shoulder. Gasket shall be adequately

protected by and permanently bonded to a metallic retainer.

2. Corrosion resistant and outdoor SLT fittings:

a. Construction:

1) PVC-coated liquid-tight fittings with a bonded 0.040-inch thick PVC coating on the

metal connector to form a seal around the SLT conduit.

2) Insulated throat and an integral sealing ring.

G. Hubs for threaded attachment of steel conduit to sheet metal enclosures:

1. Construction:

a. Insulated throat.

b. PVC coated when used in corrosive areas.

c. Bonding locknut.

d. Recessed neoprene O-ring to assure watertight and dust-tight connector.

e. One half (1/2)-inch through 1-1/4-inch steel zinc electroplated.

f. One and one half (1-1/2)-inch through 6-inch malleable iron zinc plated.

g. Usage:

h. All conduits in damp, wet, outdoor, and corrosive areas shall use threaded hubs for

connections to sheet metal enclosures.

H. Sealing fittings:

1. Construction:

a. 40 percent wire fill capacity.

b. Shall be rated for horizontal and vertical installations.

c. PVC-coated when used in corrosive areas.

d. Malleable ductile iron with steel conduit.

e. Crouse-Hinds Type EYD where drains are required.

f. Crouse-Hinds Type EYS where drains are not required.

g. UL listed for use in Class I, Division 1, Groups A, B, C, D; Class I, Division 2, Groups A, B,

C, D; Class II, Divisions 1 and 2; Groups E, F, and G.

2. Sealing compound:

a. Fiber filler and cement as recommended by the sealing fitting manufacturer.

b. Approved for the conditions and use.

1) Not affected by surrounding atmosphere or liquids.

c. Melting point shall be 200 degrees Fahrenheit minimum.




16130 - 10

I. PVC fittings:

1. Shall include the following:

a. Couplings.

b. Terminal adapters.

c. Female adapters.

d. Caps.

e. Reducer bushings.

f. Duct couplings.

g. End bells.

h. Expansion couplings.

i. Duct couplings 5 degree.

j. C - pull fittings.

k. E - pull fittings.

l. LB - pull fittings.

m. LL - pull fittings.

n. LR - pull fittings.

o. T - pull fittings.

p. X - pull fittings.

q. Service entrance caps.

2. Materials:

a. All devices shall be made of PVC, using the same materials as used for Type PVC conduit.

b. All metal hardware shall be stainless steel.

J. Through wall and floor seals:

1. Materials:

a. Body: casting of malleable or ductile iron with a hot-dip galvanized finish.

b. Grommet: neoprene.

c. Pressure rings: PVC coated steel.

d. Disc material: PVC coated steel.

e. Aluminum when used with conduit type RAC.

K. Expansion/deflection couplings:

1. Use to compensate for movement in any directions between 2 conduit ends that they

connect.

2. Shall allow movement of 3/4 inch from the normal in all directions.

3. Shall allow angular movement for a deflection of 30 degrees from normal in any direction.

4. Constructed to maintain electrical continuity of the conduit system.

5. Materials:

a. End couplings: Bronze or galvanized ductile iron.

b. Sleeve: Neoprene.

c. Bands: Stainless steel.

d. Bonding jumper: Tinned copper braid.




16130 - 11

L. Expansion couplings:

1. Shall allow for expansion and contraction of conduit:

a. Permitting 8-inch movement, 4 inches in either direction.

2. Constructed to maintain electrical continuity of the conduit system.

3. Materials:

a. Head: Malleable or ductile iron.

b. Sleeve: Steel.

c. Insulating bushing: Phenolic.

d. Finish: Hot-dip galvanized.

e. Aluminum when used with conduit type RAC.

M. Conduit markers:




EXECUTION

3.01 INSTALLATION


B. General:

1. Conduit routing:

a. The Electrical Drawings are diagrammatic in nature:

1) Install conduit runs as specified with schematic representation indicated on the

Drawings and as specified.

2) Modify conduit runs to suit field conditions, as accepted by the Engineer:

a) Make changes in conduit locations that are consistent with the design intent but

are dimensionally different, or routing to bypass obstructions.

b) Make changes in conduit routing due to the relocation of equipment.

3) The Electrical Drawings do not indicate all required junction boxes and pull boxes:

a) Provide junction boxes and pull boxes to facilitate wire pulling as required:

(1) To meet cable manufacturer’s pulling tension requirements.

(2) To limit total conduit bends between pull locations.

b) Install junction boxes and pull boxes at locations acceptable to the Engineer.

b. The Contractor is responsible for any deviations in general location, conduit size, routing,

or changes to the circuit/raceway block diagrams without the express written approval or

direction by the Engineer:

1) The Engineer is the sole source in determining whether the change is constituted as

a deviation:

2) Perform any changes resulting in additional conduits, or extra work from such

deviations.




16130 - 12

3) Incorporate any deviations on the Record Documents.

c. Owner reserves the right to deduct the amount of applicable reimbursement, equivalent

to the cost of the engineering effort required to show those unauthorized changes on

Record Drawings.

2. Use only tools recommended by the conduit manufacturer for assembling conduit system.

3. Provide adequate clearances from high-temperature surfaces for all conduit runs. Provide

minimum clearances as follows:

a. Clearances of 6 inches from surfaces 113 degrees Fahrenheit to 149 degrees

Fahrenheit.

b. Clearances of 12 inches from surfaces greater than 149 degrees Fahrenheit.

c. Keep conduit at least 6 inches from the coverings on hot water and steam pipes, 18

inches from the coverings on flues and breechings and 12 inches from fuel lines and gas

lines.

d. Where it is necessary to route conduit close to high-temperature surfaces, provide a high-

reflectance thermal barrier between the conduit and the surface.

4. Support conduit runs on water-bearing walls a minimum of 7/8-inch away from wall on an

accepted preformed channel:

a. Do not run conduit within water-bearing walls unless otherwise indicated on the

Drawings.

5. Do not install 1 inch or larger conduits in or through structural members unless approved by

the Engineer.

6. Run conduit exposed to view parallel with or at right angles to structural members, walls, or

lines of the building:

a. Install straight and true conduit runs with uniform and symmetrical elbows, offsets, and

bends.

b. Make changes in direction with long radius bends or with conduit bodies.

7. Install conduit with total conduit bends between pull locations less than or equal to 270

degrees.

8. Route all exposed conduit to preserve headroom, access space and work space and to

prevent tripping hazards and clearance problems:

a. Install conduit runs so that runs do not interfere with proper and safe operation of

equipment and do not block or interfere with ingress or egress, including equipment

removal hatches.

b. Route conduit to avoid drains or other gravity lines. Where conflicts occur, relocate

conduit as required.

9. Conduit may be run in concrete members or slabs with permission of the Engineer or as

indicated on the Drawings:

a. Refer to the typical details for conduit spacing and size requirements.

10. When installing conduit through existing slabs or walls make provisions for locating any

possible conflicting items where conduit is to penetrate. Use tone signal or X-ray methods to

make certain that no penetrations will be made into existing conduit, piping, cables, post-

tensioning cables, etc.

11. Plug conduits brought into pull boxes, manholes, handholes, and other openings until used

to prevent entrance of moisture.

12. Install conduit through wall and floor seals where indicated on the Drawings.




16130 - 13

13. For existing and new 2-inch and larger conduit runs, snake conduits with conduit cleaner

equipped with a cylindrical mandrel of a diameter not less than 85 percent of nominal

diameter of conduit:

a. Remove and replace conduits through which mandrel will not pass.

14. Provide all sleeves and openings required for the passage of electrical raceways or cables

even when these openings or sleeves are not specifically indicated on the Drawings.

15. Install complete conduit systems before conductors are installed.

16. Provide metallic conduits terminating in transformer, switchgear, motor control center or

other equipment conduit windows with grounding bushings and ground with a minimum No.

6 AWG ground wire.

17. Underground and embedded conduits:

a. Install underground conduits, including conduit runs below slabs-on-grade direct buried

and in direct buried raceway trench systems as shown on the drawings.

b. Make underground conduit size transitions at hand-holes and manholes.

C. Lighting and receptacle conduits:

1. Install conduit runs for lighting and receptacle circuits, whether or not indicated on the

Drawings:

a. Minimum conduit size:

1) 3/4 inch for exposed conduits.

2) 1 inch for underground or in slab conduits.

2. Provide conduit materials for the installed location as specified in Section 16050.

D. Conduit usage :

1. Exposed conduits:

a. Rigid conduit:

1) Install the rigid conduit type for each location as specified in Section 16050.

2) Minimum size: 3/4-inch.

b. Flexible conduit:

1) Use flexible conduit for final connections between rigid conduit and motors, vibrating

equipment, instruments, control equipment or where required for equipment

servicing:

a) Use type SLT with rigid metallic conduit.

b) Use type NFC with PVC conduit.

c) Use type EFLX in Class I Division 1 locations.

d) Use type FLX in finished areas.

2) Minimum size: 3/4-inch:

a) 1/2 when required for connection to instruments.

3) Maximum length:

Conduit Trade Size Flexible Conduit Length (in)

3/4 18

1 18

1-1/4 18

1-1/2 18




16130 - 14

Conduit Trade Size Flexible Conduit Length (in)

2 36

2-1/2 36

3 36

3-1/2 38

4 40

2. Concrete encased and embedded conduits:

a. Type PVC Schedule 40 and PVC coated rigid metallic conduit as specified below:

1) Use Type PCS in underground and embedded installation as follows:

a) Stub-up and risers to grade floor or equipment from nonmetallic conduits.

b) Entering and exiting underground or embedded conduit runs a minimum

12 inches above and below grade or finished floor.

c) For any and all bends where the total deflection is greater than 45 degrees.

b. Minimum size:

1) 2 inches in direct buried raceway trench systems unless otherwise indicated on the

Drawings.

2) 3/4" inch for in slab conduits unless otherwise indicated on the Drawings.

3. Direct buried and sand bedded conduits:

a. Type PCS.

b. Minimum size: 3/4 inch.

4. PVC coated rigid metallic conduit:

a. Use specifically manufactured or machined threading dies to manufacturer’s

specifications to accommodate the PVC jacket.

5. GRC:

a. Conduit shall be cut square and reamed before threading.

6. PVC:

a. Conduit terminations shall be via threaded adapters into threaded hubs on the junction

boxes or conduit bodies.

b. Conduit terminations into boxes without threaded hubs shall utilize a threaded adapter

and a flat neoprene washer on the outside of the box.

1) Use a locknut on the inside of the box to tighten the adapter to the box.

c. Route conduit to afford it the maximum physical protection.

1) If necessary, cover conduit to afford additional protection when it cannot be shielded

by the structure or machinery frames.

a) Use Schedule 80 where exposed runs may be subject to physical damage.

7. Conduit joints and bends:

8. General:

a. Where conduit is underground, under slabs on grade, exposed to the weather or in NEMA

Type 4 or NEMA Type 4X locations, make joints liquid-tight.

b. Keep bends and offsets in conduit runs to an absolute minimum.

c. All bends shall be symmetrical.




16130 - 15

d. The following conduit systems shall use large radius sweep elbows:

1) Underground conduits.

2) Conduits containing medium voltage cables.

3) Conduits containing shielded cables.

4) Conduits containing fiber optic cables.

e. Provide large radius factory-made bends for 1-1/4-inch trade size or larger.

f. Make field bends with a radius of not less than the requirements found in the NEC:

1) The minimum bending radius of the cable must be less than the radius of the conduit

bend.

2) Make all field bends with power bending equipment or manual benders specifically

intended for the purpose:

a) Make bends so that the conduit is not damaged and the internal diameter is not

effectively reduced.

b) For the serving utilities, make bends to meet their requirements.

g. Replace all deformed, flattened, or kinked conduit.

9. Threaded conduit:

a. Cut threads on rigid metallic conduit with a standard conduit cutting die that provides a

3/4-inch per foot taper and to a length such that all bare metal exposed by the threading

operation is completely covered by the couplings or fittings used. In addition, cut the

lengths of the thread such that all joints become secure and wrench tight just preceding

the point where the conduit ends would butt together in couplings or where conduit ends

would butt into the ends or shoulders of other fittings.

b. Thoroughly ream conduit after threads have been cut to remove burrs.

c. Use bushings or conduit fittings at conduit terminations.

d. On exposed conduits, repair scratches and other defects with galvanizing repair stick,

Enterprise Galvanizing “Galvabar” or CRC “Zinc It.”

e. Coat conduit threads with an approved electrically conductive sealant and corrosion

inhibitor that is not harmful to the conductor insulation:

1) Use KOPR-Shield as manufactured by T&B on threads of ferrous conduit.

2) Apply to the male threads and tighten joints securely.

3) Clean excess sealant from exposed threads after assembly.

f. Securely tighten all threaded connections.

g. Any exposed threaded surface must be cleaned and coated with a galvanizing solution so

that all exposed surfaces have a galvanized protective coating.

10. PVC:

a. Use approved solvent-weld cement specifically manufactured for the purpose. Spray type

cement is not allowed.

b. Apply heat for bends so that conduit does not distort or discolor. Use a spring mandrel as

required to assure full inside diameter at all bends:

1) Utilize a heater specifically for PVC conduit as recommended by the conduit

manufacturer.




16130 - 16

E. Conduit sealing and drainage:

1. Conduit drainage and sealing other than required for hazardous and classified areas:

a. Provide sealing and drainage in vertical drops of long (in excess of 20 feet), exterior,

above grade conduit runs at the points at which the conduit enter buildings, switchgear,

control panels, lighting panel-boards, and other similar enclosures.

b. Provide seal fittings with drains in vertical drops directly above grade for exterior, above

grade conduit runs that are extended below grade.

c. Provide conduit seals with drains in areas of high humidity and rapidly changing

temperatures:

1) Where portions of an interior raceway pass through walls, ceilings or floors that

separate adjacent areas having widely different temperatures.

d. Provide conduit seals similar to O/Z Gedney (Type CSM) on all conduits between

corrosive and non-corrosive areas.

e. Seal one end only of all underground conduits at highest point with O/Z Gedney sealing

(non-hazardous) filling, or equal.

2. Install seals with drains at any location along conduit runs where moisture may condense or

accumulate. This requirement includes, but is not limited to, the following locations: control

panels, junction boxes, pull-boxes, or low points of conduit.

3. All conduits which enter/leave a building shall be sloped away from the building to prevent

the accumulation of water within the building.

4. All conduits which enter/leave a building shall be sealed with an approved duct seal.

5. Conduit supports:

6. General:

a. Provide appropriate hangers, supports, fasteners, and seismic restraints to suit

applications:

1) As specified in Section 16070.

2) Provide support materials consistent with the type of conduit being installed as


b. Support conduit at the intervals required by the NEC.

c. Perforated strap and plumbers tape are not acceptable for conduit supports.

7. Above suspended ceilings:

a. Support conduit on or from the structure, do not support conduit from hanging wires or

suspended ceiling grid.

8. Concealed conduit on wood:

a. Use 2-hole galvanized steel straps screwed or nailed to the wood or hammer-driven

stamped galvanized type supports having serrated or saw-tooth edges on the driven

portion and designed specifically for the size and type of conduit being supported. Drive

these latter supports so that the conduit is tightly and rigidly supported. Replace any

dented or damaged conduit.

9. In steel stud construction:

a. Tie conduit at maximum 4-foot intervals with No. 16 gauge double annealed galvanized

wire or conduit clips so that conduit cannot move from vibration or other causes.

10. Conduit on concrete or masonry:

a. Use 1-hole malleable iron straps with metallic or plastic expansion anchors and screws or

support from preset inserts.




16130 - 17

b. Use preset inserts in concrete when possible.

c. Use pipe spacers (clamp backs) in wet locations.

d. On plaster or stucco, use 1-hole malleable iron straps with toggle bolts.

11. Conduit on metal decking:

a. Use 1-hole malleable iron straps with 1-inch long cadmium-plated Type A panhead sheet

metal screws. Fully or partially hammer-driven screws are not acceptable.

12. Suspended conduit:

a. Use malleable iron factory-made split-hinged pipe rings with threaded suspension rods

sized for the weight to be carried (minimum 3/8-inch diameter), Kindorf, or equal.

b. For grouped conduits, construct racks with threaded rods and tiered angle iron or

preformed channel cross members. Clamp each conduit individually to a cross member.

Where rods are more than 2 feet long, provide rigid sway bracing.

13. Supports at structural steel members:

a. Use beam clamps.

b. Drilling or welding may be used only as specified or with approval of the Engineer.

14. PCS systems:

a. Provide right angle beam clamps and U bolts specially formed and sized to snugly fit the

outside diameter of the coated conduit. Provide "U" bolts with PVC encapsulated nuts

that cover the exposed portions of the threads.

b. Securely fasten exposed conduits with Type 316 stainless steel clamps or straps.

F. Expansion or expansion/deflection fittings:

1. General:

a. Align expansion coupling with the conduit run to prevent binding.

b. Follow manufacturer’s instructions to set the piston opening.

c. Install expansion fittings across concrete expansion joints and at other locations where

necessary to compensate for thermal or mechanical expansion and contraction.

d. Furnish fittings of the same material as the conduit system.

2. For metallic conduit (PCS, PCA, GRC and RAC) provide expansion or expansion/deflection

couplings, as appropriate, where:

a. Install expansion fittings a minimum of every 200 feet in straight conduit runs.

3. For PVC provide expansion or expansion/deflection couplings, as appropriate, where length

change due to temperature variation exceeds 2 inches:

a. Rigidly fix the outer barrel of the expansion coupling so it cannot move.

b. Mount the conduit connected to the piston loosely enough to allow the conduit to move

as the temperature changes.

G. Empty conduits:

1. Provide a polyethylene rope rated 250 pounds tensile strength in each empty conduit more

than 10 feet in length.

2. Provide one empty 3/4-inch conduit for each four spare unused circuits or spaces of each

flush mounted branch circuit panel-board. Terminate empty 3/4-inch conduits in individual

junction boxes that are accessible to enable extension of future branch circuits.




16130 - 18

3. Seal ends of all conduit with approved, manufactured conduit seals, caps or plugs

immediately after installation:

a. Keep ends sealed until immediately before pulling conductors.

H. PCS Damaged Conduits

1. PCS conduits that have damaged PVC coating shall be replaced, no exceptions. Field repair

shall not be acceptable.

I. Miscellaneous:

1. Seal roof penetrations for raceways and other items that penetrate the roof in accordance

with roofing manufacturer’s instructions and as indicated on the Drawings.

2. Provide electrical unions at all points of union between ends of rigid conduit systems that

cannot otherwise be coupled:

a. Running threads and thread-less couplings are not allowed.

3. Replace any conduit installed that the Engineer determines does not meet the requirements

of this Specification.



3.03 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Boxes



16134 - 1

SECTION 16134

BOXES

GENERAL

1.01 SUMMARY


1. Device boxes.

2. Raceway system boxes.











a. Section 01330, Submittal Procedures.

b. Section 16050, Common Work Results for Electrical.

1.02 REFERENCES



1. A 47 - Standard Specification for Ferritic Malleable Iron Castings.

2. D 149 - Standard Test Method for Dielectric Breakdown Voltage and Dielectric

Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies.

3. D 495 - Standard Test Method for High-Voltage, Low-Current, Dry Arc Resistance of

Solid Electrical Insulation.

4. D 570 - Standard Test Method for Water Absorption of Plastics.

5. D 648 - Standard Test Method for Deflection Temperature of Plastics Under Flexural

Load in the Edgewise Position.

6. D 790 - Standard Test Methods for Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials.

7. D 792 - Standard Test Methods for Density and Specific Gravity (Relative Density) of

Plastics by Displacement.

C. Joint Industry Conference (JIC).


1. 94 - Standard for Tests for Flammability of Plastic Materials for Parts in Devices and

Appliances.




16134 - 2

1.03 DEFINITIONS



1. Arcing parts: Circuit breakers, motor controllers, switches, fuses, or any device

intended to interrupt current during its operation.

2. Raceway system boxes: Boxes that are used for wire and cable pull-boxes, conduit

junction boxes, or terminal boxes.


A. Provide outlet boxes for devices such as switches, receptacles, telephone and computer

jacks, security systems, junction, and pull-boxes for use in the raceway systems, etc.

B. Provide boxes and conduit bodies as indicated on the Drawings or as needed to

complete the raceway installation.

1.05 SUBMITTALS


B. Product data:

1. Manufacturer.

2. Materials.

3. Dimensions:

a. Height.

b. Width.

c. Depth.

d. Weight.

e. NEMA rating.

4. Conduit entry locations.


6. Installation instructions.

C. Shop drawings:

1. Include identification and sizes of pull boxes.




1. Outlet boxes shall comply with all applicable standards of:

a. JIC.

b. NEC.




16134 - 3

c. NEMA.

d. UL.





1.09 SEQUENCING


1.10 SCHEDULING (NOT USED)

1.11 WARRANTY




PRODUCTS

2.01 MANUFACTURERS


1. Pressed steel boxes:

a. Steel City.

b. Appleton.

c. Crouse - Hinds.

d. Thomas & Betts.

2. Plastic coated steel boxes:

a. Rob Roy.

b. OCAL.

3. Cast device boxes:

a. Appleton.

b. Crouse - Hinds.

c. OZ/Gedney.

4. Formed steel enclosures:

a. Hoffman.

b. Thomas and Betts.

c. Stahlin.

d. Rittal.




16134 - 4

5. Stainless steel enclosures:

a. Hoffman.

b. Stahlin.

c. Rittal.

6. Pressed steel boxes and concrete boxes:

a. Appleton.

b. Steel City.

c. Cooper/Crouse Hinds.

d. OZ Gedney.


A. Pressed steel boxes:

1. One-piece galvanized pressed steel.

2. Knockout type boxes.

3. Minimum size 4-inch square by 3-1/2-inch deep.

B. Concrete boxes:

1. For outlets and pull boxes in concrete construction.

2. Pressed steel or cast construction, concrete tight.

3. Knockout sizes range from 1/2 inch to 1 inch.

4. Depth as needed.

5. Types:

a. Four-inch octagon.

b. Four-inch octagon ceiling boxes with hanging bars.

c. Gangable masonry boxes:

1) 3-1/2-inch deep, 3-3/4-inch high, length as required:

a) 3-1/2-inch deep boxes may be used where wall thickness

precludes the use of the deeper boxes.

2) With partitions as needed.

C. Threaded-hub boxes:

1. Construction:

a. With internal green ground screw.

b. Furnished with a suitable gasketed cover.

c. With integral cast mounting lugs when surface mounted.

d. Conduit sizes range from 3/4 inch to 1 inch.

e. Tapered threaded hubs with integral bushing.

2. Malleable iron boxes:

a. Conforming to ASTM A 47 Grade 32510.

D. Plastic coated threaded-hub boxes:

1. Construction:

a. With internal green ground screw.




16134 - 5

b. Furnished with a suitable gasketed cover.

c. With integral cast mounting lugs when surface mounted.

d. Conduit sizes range from 3/4 inch to 1 inch.

e. Double coated with a nominal 0.002-inch (2 mil) urethane on both the interior

and exterior before application of PVC coating.

f. Shall be FD-type, 2.69” deep minimum with mounting lugs and integral grounding

screw.

g. With a minimum 0.040-inch (40 mil) PVC coating bonded to exterior.

h. With pressure sealing sleeve to protect the connection with conduit.

E. Class I, Division 2 areas:

1. For boxes not containing arcing parts:

a. As specified in Section 16050, Common Work Results for Electrical.

b. Pressed metal boxes are not allowed.

2. For boxes containing arching parts provide:

a. Boxes designed and listed for Class I Division 1 locations and group type

atmosphere in which they will be used:

1) The approval ratings must be permanently marked on each item.

3. Cast iron box and cover.

4. Precision machined flame path between box and cover with neoprene O-ring.

5. Bolt-on stainless steel slotted mounting feet for horizontal or vertical mounting.

6. For applications requiring hinged cover, provide flexible hinge mounting either left or

right side.

7. External flange.

8. Shall be provided with manufacturer supplied backpanel.

9. Ground lug.

F. Formed steel enclosures:

1. Steel:

a. NEMA Type 12.

b. Fabricated from 14-gauge steel, minimum.

c. All seams continuously welded ground smooth.

d. Door:

1) Rolled lip around 3 sides.

2) Attached to enclosure by means of a continuous stainless-steel hinge and

pin.

e. Neoprene door gasket to provide a watertight, dust-tight, oil-tight seal:

1) Attached with an adhesive.

2) Retained by a retaining strip.

f. Fabricate all external removable hardware for clamping the door to the enclosure

body from zinc-plated heavy gauge steel:

1) With a hasp and staple for padlocking.

g. Provide large enclosures with door and body stiffeners for extra rigidity.

h. No holes or knockouts.




16134 - 6

i. Finish:

1) ANSI-61 gray electrostatically applied polyester powder inside and out over

cleaned and primed surfaces.

2) White electrostatically applied polyester powder mounting plate.

j. Heavy gauge steel external mounting brackets when surface mounted.

k. Shall be provided with manufacturer supplied backpanel.

l. Provide manufacturer supplied hinged deadfront where shown on the drawings.

2. Stainless steel:

a. NEMA Type 4X:

1) Boxes in locations subject to flooding or temporary submersion:

b) NEMA Type 6.

b. Fabricated from 14-gauge Type 316 stainless steel.

c. All seams continuously welded.

d. Door:

1) Rolled lip around 3 sides.

2) Attached to enclosure by means of a continuous stainless-steel hinge and

pin.

e. Neoprene door gasket to provide a watertight seal:

1) Attached with an adhesive.

2) Retained by a retaining strip.

f. Fabricate all external removable hardware for clamping the door to the enclosure

body from heavy gauge stainless steel:

1) With a hasp and staple for padlocking.

g. Provide large enclosures with door and body stiffeners for extra rigidity.

h. No holes or knockouts.

i. Finish:

1) Brushed.

j. Stainless steel external mounting brackets when surface mounted.

k. Shall be provided with manufacturer supplied backpanel.

l. Provide manufacturer supplied hinged deadfront where shown on the drawings.

G. Cast iron junction boxes:

1. NEMA Type 4, 2.69” deep.

2. Recessed cover boxes.

3. Suitable for use outdoors where subject to rain, dripping, or splashing water.

4. Designed for flush mounting in walls or floors:

a. Can be surface mounted using mounting lugs.

5. Construction:

a. Cast iron box.

b. Covers:

1) Checkered plate covers suitable for foot traffic.

2) When used in areas subject to vehicular traffic H-20 loading.

c. Hot dip galvanized.




16134 - 7

d. Neoprene gasket.

e. Stainless steel screw covers.

2.03 ACCESSORIES

A. Fasteners:

1. Electroplated or stainless steel in boxes with wiring devices.

2. Screws, nuts, bolts, and other threaded fasteners:

a. Stainless steel.

B. Internal panels:

1. Provide internal panels where required for mounting of terminal strips or other

equipment.

2. With plated steel shoulder studs.

3. Steel with white polyester powder finish.

EXECUTION

3.01 INSTALLATION


B. General:

1. Provide materials and construction suitable for environmental conditions at the

location of the box as specified in Section 16050.

2. Provide outlet box materials to match the conduit system:

a. GRC - Cast ferrous boxes.

b. PCS - PVC coated cast ferrous boxes.

c. PVC - PVC boxes.

3. Solid type gang boxes:

a. For more than 2 devices.

b. For barriered outlets.

4. Support all wall mounted NEMA Type 4 or NEMA Type 4X boxes to maintain a

minimum of 7/8-inch free air space between the back of the enclosure and the wall:

a. Use machined spacers to maintain air space; built-up washers are not

acceptable.

b. Use stainless steel or nylon materials for spacers.

5. In finished areas:

a. Provide specific pull or junction boxes only as indicated on the Drawings or as

directed.

6. Fit all cast boxes and pressed steel boxes for flush mounting in concrete with cast,

malleable box covers and gaskets.

7. In terminal boxes, furnish terminals as indicated on the Drawings, with a minimum of

50 percent spare terminals:

a. Furnish wireways for discrete and analog/DC wiring.

b. Separate analog wiring from 120 V discrete or power wiring.




16134 - 8

8. For fire-rated construction, provide materials and installation for use in accordance

with the listing requirements of the classified construction.

9. All boxes and enclosures installed outdoors shall have hinges installed on the sides

of the enclosure. No hinges on the top of the box or enclosure shall be permitted.

10. Conduits shall not enter the top of boxes in wet locations or in locations where

subject to water.

11. Use cast malleable iron boxes when box must support other devices.

12. Boxes serving luminaires or devices :

a. Use as pull boxes wherever possible.

13. Size boxes in accordance with NEC requirements and to provide sufficient room for

the future components and cables indicated on the Drawings.

C. Outlet boxes:

1. Locate outlet boxes as indicated on the Drawings:

a. Adjust locations so as not to conflict with structural requirements or other trades.

2. Use deep threaded-hub malleable iron or aluminum boxes:

a. In hazardous areas.

b. Where exposed to the weather.

c. In unheated areas.

d. Where subject to mechanical damage:

1) Defined as exposed boxes less than 10 feet above the floor.

e. To act as a pull box for conductors in a conduit system.

f. Accommodate wiring devices.

3. Use deep threaded-hub plastic coated malleable iron boxes in corrosive and NEMA

Type 4X area and when the conduit system is PVC coated steel.

4. Outlet boxes may be used as junction boxes wherever possible.

D. Pull boxes and junction boxes:

1. Size pull boxes in accordance with NEC requirements and to provide sufficient room

for any future conduits and cables as indicated on the Drawings.

2. Install pull boxes such that access to them is not restricted.

E. For boxes not indicated:

1. Provide types and mountings as required to suit the equipment and that will be

consistent with the conduit system and environmental conditions as indicated in

Section 16050.

2. Outlet, switch, and junction boxes for flush-mounting in general purpose locations:

a. One-piece, galvanized, pressed steel.

3. Ceiling boxes for flush mounting in concrete:

a. Deep, galvanized, pressed steel.

4. Outlet, switch, and junction boxes where surface mounted in exposed locations:

a. Cast ferrous boxes with mounting lugs, zinc or cadmium plating finish.




16134 - 9

5. Outlet, control station, and junction boxes for installation in corrosive locations:

a. Fiberglass reinforced polyester, stainless steel, or plastic-coated steel to match

the conduit system.

b. Furnished with mounting lugs.

F. Recessed boxes:

1. Support recessed boxes in suspended ceilings or stud partitions with galvanized steel

box hangers of types made specifically for the purpose or attach directly to wood

members or blocking.

2. Secure hangers or boxes to wood with 1-inch long cadmium-plated Type A pan head

screws:

a. Fully or partially hammer-driven screws are not acceptable.



3.03 CLEANING


3.04 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Wiring Devices



16140 - 1

SECTION 16140

WIRING DEVICES

GENERAL

1.01 SUMMARY


1. Switches.

2. Receptacles.

3. Plates.













1.02 REFERENCES


B. Federal Specifications (FS):

1. W-C 596 - Connector, Electrical, Power, General Specification for.

2. W-S 896/2 - Switches, Toggle (Toggle and Lock), Flush Mounted (General

Specification).

C. National Electrical Manufacturers Association (NEMA):

1. WD1 - General Color Requirements for Wiring Devices.

2. ICS 5 - Industrial Control and Systems, Control Circuit and Pilot Devices.

3. OS1 - Sheet-Steel Outlet Boxes, Device Boxes, Covers and Box Supports.

4. WD6 - Wiring Devices Dimensional Specifications.

D. Underwriters Laboratories Inc. (UL):

1. 20 - General Use Snap Switches.

2. 498 - Standard for Attachment Plugs and Receptacles.

3. 514D - Cover Plates for Flush-Mounted Wiring Devices.

4. 943 - Ground-Fault Circuit-Interrupters.

5. 1472 - Solid State Dimming Controls.




16140 - 2

1.03 DEFINITIONS



1. GFCI: Ground fault circuit interrupter.

2. P-S: Pass and Seymour.

3. Cooper: Cooper Wiring Devices, a division of Cooper Industries.

4. T&B: Thomas and Betts.


A. Switches, receptacles, and plates as indicated on the Drawings wired and operable to

form a complete system.

1.05 SUBMITTALS


B. Product data:


C. Shop drawings:

1. Engraving schedule:

a. Furnish complete engraving schedule for engraved nameplates.



B. Wiring devices shall be UL listed and labeled.





1.09 WARRANTY







16140 - 3

PRODUCTS

2.01 MANUFACTURERS

A. Switches:


a. Hubbell.

b. Leviton.

c. Cooper.

2. Switches for hazardous areas: One of the following or equal:

a. Appleton.

b. Crouse-Hinds.

3. Occupancy Sensor Switches: The following or equal:

a. WattStopper.

b. Cooper.

4. Dimmer switches: The following or equal:

a. Lutron.

b. Cooper.

B. Receptacles:

1. General purpose receptacles: One of the following or equal:

a. Hubbell.

b. Leviton.

c. Cooper.

2. Receptacles for hazardous areas: One of the following or equal:

a. Crouse-Hinds.

b. Appleton.

3. 480-Volt, 3-phase receptacles: One of the following or equal:

a. Crouse-Hinds.

b. Hubbell.

c. Russellstol™.

C. Plates:

1. General location: The following or equal:

a. P-S.

b. Cooper.

2. Wet or corrosive areas: One of the following or equal:

a. Hubbell.

b. Cooper.

c. T&B.

d. P-S.




16140 - 4

3. In-use covers: One of the following or equal:

a. TayMac.

b. Cooper.

c. P-S.

d. T&B.


A. Switches:

1. General:

a. 120-277 VAC.

b. 20 ampere.

c. Listed in accordance with UL 20.

d. Designed and constructed in accordance with FS W-S-896/2.

e. Back and side wired unless otherwise indicated.

f. Integral grounding terminal.

g. Totally enclosed:

1) Color-coded body with color corresponding to ampere rating.

h. Provide switches with the operator style and contact arrangement as indicated on

the Drawings and as required for proper operation.

i. Color:

1) Ivory in finished areas.

2) Brown in all other areas.

2. General purpose switches:

a. Toggle type.

3. Switches for office areas:

a. Rocker type.

b. Rectangular.

4. Switches for use with photocell:

a. Maintained contact.

b. Two circuit.

c. Three position:

1) Center off.

5. Switches for hazardous areas:

a. Suitable for use in Class I Division 1 and Class I Division 2 locations.

b. Factory sealed.

c. Through-feed or dead-end as required.

6. Occupancy sensor switches:

a. Wall switch with dual-technology passive infrared and ultrasonic sensor.

1) Configured such that lights turn on only when both infrared and ultrasonic

sensors detect activity, but do not turn off as long as either sensor detects

activity.




16140 - 5

b. Selectable “automatic-on” mode activated by sensors or “manual-on” mode

activated by pushbutton.

c. Adjustable 5-30 minute time delay.

d. Selectable audible alert as a warning before lights turn off.

e. Rated for fluorescent lighting loads of up to 800W.

f. True multi-way switching allowing identical controls at any location for multi-way

switching applications.

7. Dimmer switches:

a. Shall be rectangular design with LED light level indicators.

b. Suitable for use with type of lamp switched.

8. Twist Timers:

a. Stainless steel faceplate.

b. Twist-style, spring-wound.

c. Two (2) hours with 5-minute intervals marked on faceplate.

d. Commercial-grade.

B. Receptacles:

1. General purpose receptacles:

a. Single or duplex as indicated on the Drawings.

b. 125 VAC.

c. 20 ampere or as indicated on the Drawings.

d. NEMA Type 5-20R configuration for 20 ampere receptacles.

e. Other NEMA configurations as indicated on the Drawings.

f. Listed in accordance with UL 498.

g. Designed and constructed in accordance with FS W-C-596.

h. Back and side wired.

i. One-piece, rivet-less mounting strap.

j. Color:

1) Ivory in finished areas.

2) Brown in all other areas.

3) Orange when powered by a UPS.

2. Ground fault interrupter receptacles (GFCI):

a. 125 VAC.

b. 20 ampere.

c. Trip level 4-6 milliampere.

d. Individual and feed through protection.

e. UL 943 and UL 498 listed.

f. NEMA Type 5-20R configuration.

g. For damp or wet locations:

1) Weather resistant, in accordance with UL 498.




16140 - 6

3. 480-volt 3-phase Receptacles

a. 480-volt, 30-amp, 10-horsepower.

b. Switch rated.

c. 3-pole plus ground.

d. IP66/67 and NEMA 4X rated.

e. Provide with two auxiliary / pilot contacts.

f. Provide with manufacturer supplied FD-type junction box and 30-degree nylon

angle.

4. 480-volt 3-phase Inlet

a. 480-volt, 30-amp, 10-horsepower.

b. Compatible and of the same manufacturer as the 480-volt 3-phase receptacle.

c. Switch rated.

d. 3-pole plus ground.

e. IP66/67 and NEMA 4X rated.

f. Provide with two auxiliary / pilot contacts

g. Provide poly handle with 3/4” NPT.

C. Single-Ended Cordsets

1. #16 AWG CU yellow STOOW cable with US color code.

2. Oil resistant PVC jacket.

3. Non-metallic coupling nut.

4. 6-foot cable length minimum.

5. Available in in 2-pole through 6-pole. Provide cordsets with number of poles as

shown on the Drawings.

6. Provide straight end connectors, male and female receptacles.

D. Plates:

1. General location:

a. Type 302 or 304 stainless steel.

b. Brushed satin finish.

c. Minimum thickness: 0.032 inches.

d. Rectangular or square shape.

e. Labeling:

1) Provide each switch plate with the following:

a) Panel (source).

b) Circuit number.

c) Refer to CWS Equipment Tag Numbering Standards.

2) Characters shall be block letter pantograph engraved with a minimum

character height of 1/8-inch.

f. Coordinate the number of gangs, number, and type of openings with the specific

location.




16140 - 7

2. Outdoor and wet areas requiring NEMA Type 4 or NEMA Type 4X enclosures:

a. General:

1) UL listed for wet locations.

2) Gasketed.

3) Die cast metal:

d) Match material to box material.

b. Switches:

1) Lever operated:

e) Provide toggle switch.

c. Receptacles:

1) Weather proof in-use cover:

f) Die cast metal construction with electrostatic powder coating for

corrosion resistance.

g) Gasketed.

h) Lockable.

i) UL listed and in accordance with NEC.

3. Corrosive areas:

a. Neoprene.

b. Gasketed.

c. Weatherproof.

E. Data and communications jacks:

1. Process network jacks - panel/enclosure mounted:

a. Network jacks located in process areas shall have a NEMA Type 4 rating (with

closure cap).

b. Mounting of network jacks in control panels shall be accomplished using

bulkhead connectors and environmental enclosure caps, which are permanently

attached to the bulkhead fitting.

c. Network jacks shall have RJ-45 connections on both sides of connector

(bulkhead pass through) allowing for direct connection to the network switch and

computer with standard patch cords. No punch down PC board connections shall

be allowed.

d. Manufactured by Woodhead Connectivity RJLNXX.

2. Process network jacks - conduit body mounted:

a. Network jacks located in process areas shall have a NEMA Type 4 rating (with

closure cap).

b. Mounting of network jacks in conduit bodies adapter (with minifast connector)

shall be accomplished using conduit body insert and environmental enclosure

caps.

c. PC board connections shall not be allowed.

d. Furnish RJ-45 to minifast connector patch cable 3 feet in length.

e. Manufactured by InterlinkBT RSS series.




16140 - 8

3. Network/phone jacks:

a. Network jacks located in computer rooms shall be installed per the installation

details indicated on the Drawings.

b. Standard Decora wall plates shall be used with QuickPort modules and inserts.

c. Plugs shall be color coded as indicated in the installation details indicated on the

Drawings.

d. Manufactured by Leviton Quickport series.

EXECUTION

3.01 INSTALLATION


B. Mounting heights:

1. Process and production areas:

a. Switches and receptacles 48 inches from finished floor to top of plate.

2. Offices and finished areas:

a. Switches: 48 inches from finished floor to top of plate.

b. Receptacles: 18 inches from finished floor to center of plate.

C. Switches:

1. Over 300 Volts:

a. Where switches used in systems of more than 300 volts between conductors, are

to be ganged in outlet boxes, provide switches having no exposed live parts or

use barriers between the individual switches.

D. Receptacles:

1. Provide GFCI receptacles as indicated on the Drawings.

a. Provide weather resistant GFCI receptacles in all wet or damp areas.


2. Mount non-weatherproof receptacles vertically:

a. Ground slot down.

3. Mount weatherproof receptacles horizontally:

a. Neutral slot up.

4. 3-phase receptacles shall be consistent with respect to phase connection at the

receptacle terminals. Correct errors in phasing at the source and not the receptacle.

E. Single-Ended Cordsets

1. Provide single-ended cordsets as the disconnecting means for wiring to instrument

transmitters.

F. Ensure all plates make a firm seal with wall for recessed mounted devices:

1. Outside edges of plates parallel with building lines.




16140 - 9





B. Demonstrate the following to the Engineer and Owner:

1. Switching is as indicated on the Drawings.

2. All circuits conform to the panel schedules.

3. All ground fault receptacles operate at levels below or equal to OSHA maximum

allowable fault levels.

3.04 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Low Voltage Wire Connections



16150 - 1

SECTION 16150

LOW VOLTAGE WIRE CONNECTIONS

GENERAL

1.01 SUMMARY


1. Wire connecting devices.

2. Terminations.

3. Splices.













c. Section 16123, 600 Volt or Less Wires and Cables.

1.02 REFERENCES



1. D 3005 – Standard Specification for Low-Temperature Resistant Vinyl Chloride

Plastic Pressure-Sensitive Electrical Insulating Tape.

C. CSA International (CSA):

1. C22.2 - No.197-M1983 (R2208) - PVC Insulating Tape.


1. 510 - Standard for Polyvinyl Chloride, Polyethylene, and Rubber Insulating Tape.

1.03 DEFINITIONS



A. Provide a complete system of wiring connectors, terminators, fittings, etc. for a complete

wiring system suitable for the cables and conductors used.




16150 - 2

1.05 SUBMITTALS


B. Product data:


2. Installation instructions.



B. All materials shall be UL listed.





1.09 WARRANTY




PRODUCTS

2.01 MANUFACTURERS

A. Manufacturers for each type of technology are specified with the equipment in this

Section.

2.02 EQUIPMENT

A. Control connections:

1. Use insulated ring type wire terminators for connections to all screw terminals:

a. With chamfered/funneled terminal barrel entry.

b. Deep internal serrations.

c. Long barrel design to reduce electrical resistance and increased insulator-barrel

surface area to ensure that the insulator remains in contact with the barrel.

d. Electroplated-tin copper conductor.

e. Manufacturer: One of the following or equal:

1) Thomas and Betts, Stakon.

2. For process equipment connections work from manufacturer's drawings.




16150 - 3

B. Joints, splices, taps, and connections:

1. 600-volt conductors:

a. Use solderless connectors.

b. Use only plated copper alloy connectors or lugs:

1) Aluminum connectors or lugs are not acceptable for copper conductors.

c. Under those specific conditions where aluminum conductors have been allowed

or are specified then the connectors for aluminum conductors shall be

specifically designed for that purpose.

d. For lighting and receptacle circuits with wire Number 10 AWG and smaller use

compression splice caps, with insulating caps:

1) Manufacturer: One of the following or equal:

a) Ideal: Winged wire connectors.

e. For all other circuits, use heavy duty copper compression connectors:


a) Burndy.

b) Thomas and Betts.

f. Heat shrink tubing:

1) Suitable for indoors, outdoors, overhead, direct burial or submerged

applications.

2) Minimum shrink ratio: 4 to 1.

3) Continuous operating temperature: -55 degrees Celsius to 110 degrees

Celsius.

4) Internally applied adhesive sealant.

5) Cross-linked polyolefin:

a) Manufacturers, one of the following or equal:

(1) 3M ITCSN.

(2) Thomas & Betts Shrink-Kon.

2. Instrumentation class cable splices:

a. Suitable for indoor, outdoors, weather exposed, direct buried, or submersed

applications.

b. Utilizing an epoxy, polyurethane, and re-enterable compounds.

c. For use with shielded or unshielded plastic- and rubber-jacketed, signal, control,

and power cables rated up to 1 kilovolt.

d. Two-part mold body with tongue and groove seams and built in spacer webbing.

e. Manufacturer: One of the following or equal:

1) 3M - Scotchcast 72-N.

C. Insulating tape:

1. General purpose insulating tape:

a. Minimum 7 mil vinyl tape.

b. Suitable for application in an ambient of -18 degrees Celsius

(0 degrees Fahrenheit).

c. Operating range up to 105 degrees Celsius (220 degrees Fahrenheit).

d. Flame retardant, hot- and cold- weather resistant, UV resistant.




16150 - 4

e. For use as a primary insulation for wire cable splices up to 600 VAC.

f. Meeting and complying with:

1) ASTM D 3005 Type I.

2) UL 510.

3) CSA C22.2.

g. Manufacturer: One of the following or equal:

1) 3M - Scotch Number Super 33+.

2. General-purpose color-coding tape:

a. Minimum 7 mil vinyl tape.

b. Suitable for application on PVC and polyethylene jacketed cables.

c. For use indoors and outdoors in weather protected enclosures.

d. Available with the following colors:

1) Red.

2) Yellow.

3) Blue.

4) Brown.

5) Gray.

6) White.

7) Green.

8) Orange.

9) Violet.

e. For use as phase identification, marking, insulating, and harnessing.

f. Meeting and complying with:

1) UL 510.

2) CSA C22.2.


1) 3M - Scotch Number 35.

EXECUTION

3.01 INSTALLATION


B. Load connections:

1. Connect loads to the circuits as indicated. Color-code all branch circuits as specified

in Section 16123.

C. Zero to 600-volt systems:

1. Make all connections with the proper tool and die as specified by the device

manufacturer.

2. Use only tooling and dies manufactured by the device manufacturer.




16150 - 5

3. Insulate all connections and splices with Scotch 33+ tape and Scotchfill, or pre-

molded plastic covers, or heat shrink tubing and caps.

4. Number all power and control wires before termination.

D. Motor connections (600 volts and below):

1. Terminate wires with compression type ring lugs at motors.

2. Connection at both the motor leads and the machine wires shall have ring type

compression lugs.

3. Cover bolted connectors with a heat shrinkable, cross-linked polyolefin material

formed as a single opening boot:

a. In damp and wet locations, use a complete kit containing mastic that shall seal

out moisture and contamination.

b. Shrink cap with low heat as recommended by manufacturer.

4. Wire markers shall be readable after boot installation.

5. Manufacturer: One of the following or equal:

a. Raychem MCK.



3.03 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Low Voltage Motors Up To 500 Horsepower



16222 - 1

SECTION 16222

LOW VOLTAGE MOTORS UP TO 500 HORSEPOWER

GENERAL

1.01 SUMMARY


1. Low voltage motors up to 500 horsepower (hp):

a. Furnished separately.

b. Part of driven equipment specified in other sections.

c. Other electric motors required for a complete installation.













c. Section 16950 - Field Electrical Acceptance Tests.

1.02 REFERENCES


B. American Bearing Manufacturers Association (ABMA):

1. 9 - Load Ratings and Fatigue Life for Ball Bearings.

2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

C. American Petroleum Institute (API):

1. 670 - Vibration, Axial Position, and Bearing Temperature Monitoring Systems.

D. ASTM International (ASTM).

1. B-117 - Standard Practice for Operating Salt Spray (Fog) Apparatus.

E. Institute of Electrical and Electronic Engineers (IEEE):

1. 43 - IEEE Recommended Practice for Testing Insulation Resistance of Rotating

Machinery.

2. 112 - IEEE Standard Test Procedure for Poly-phase Induction Motors and Generators.

3. 114 - Standard Test Procedure for Single-Phase Induction Motors.




16222 - 2

4. 303 - Recommended Practice for Auxiliary Devices for Rotating Electrical Machines in

Class I, Division 2 and Zone 2 Locations.

5. 841 - Standard for Petroleum and Chemical Industry-Premium-Efficiency, Severe

Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors - Up to and

Including 370 kW (500hp).

6. 1349 - Guide for Application of Electric Motors in Class I, Division 2 Hazardous

(Classified) Locations.

F. National Electrical Manufacturers' Association (NEMA):

1. MG-1 - Motors and Generators.

2. MG-2 - Safety Standard for Construction and Guide for Selection, Installation, and

Use of Electric Motors and Generators.

G. Underwriters Laboratories Inc. (UL):

1. 674 - Electric Motors and Generators for Use in Division 1 Hazardous (Classified)

Locations.

1.03 DEFINITIONS



A. Furnish and install electric motors and accessories as specified in this Section and the

Sections specifying driven equipment to provide a complete and operable installation.

1.05 SUBMITTALS


B. Submit completed motor data sheets for each motor supplied:

1. Conform to data sheet in the appendix of this Section.

2. Manufacturer’s or other data sheets are not acceptable.

C. Product data:

1. Descriptive bulletins.

2. Machine tag and loop number as indicated on the Drawings and in the specification

section number of the driven machine.

3. Complete electrical data.

a. Rated size of motor, hp, and service factor

b. Efficiency at full, ¾ and ½ load

c. Full load current

d. Locked rotor current

4. Temperature rise and insulation rating

5. Type of bearing and method of lubrication




16222 - 3

6. Torque, current, and power factor vs. speed curves:

a. At 100 percent rated voltage for all full voltage started and VFD driven motors.

b. For motors on reduced voltage start at 70, 80, 90 and 100 percent rated voltage.

7. Additional data for motors installed in classified areas:

a. Temperature code.

b. Hazardous area approval indicating Class, Division and Group:

1) For motors driven by variable frequency drives, provide manufacturer’s

certification that the motor is suitable for operation in the hazardous area

when driven by a variable frequency drive.

8. Accessories data:

a. Power factor correction capacitors:

1) Size in KVAR, for all motors not connected to variable frequency drives.

b. Motor winding heaters:

1) Voltage.

2) Watts.

c. Winding temperature detectors:

1) Type.

2) Rating.

d. Moisture detectors.

9. Mechanical data:

a. Bearing design and bearing life calculations.

b. Resonant frequencies for all VFD-driven motors 50 hp or greater.

10. List of manufacturer recommended spare parts.

D. Shop drawings:

1. Motor weight.

2. Frame size.

3. Conduit box (es), size(s), and location(s).

4. Outline drawings with dimensions.

5. Installation details for the project seismic criteria.

E. Test reports:

1. Factory test reports with test reference standard identified.

F. Certification:

1. When motors are driven by variable speed drive systems, submit certification that

selected motor:

a. Is capable of satisfactory performance under the intended load.

b. Meets the requirements of the latest edition of NEMA MG-1 Part 31.

c. Is matched to the type of variable frequency drive specified.

G. Calculations:

1. Where site conditions specified in Section 16050 exceed manufacturer’s ratings,

provide derating calculations for each motor.




16222 - 4





B. Motors 200hp and larger:

1. Rotate shaft 90 degrees once per month.



1.09 WARRANTY




PRODUCTS

2.01 MANUFACTURERS


1. Nidec/US Motors.

2. WEG.

3. ABB/Baldor/Reliance.

2.02 EQUIPMENT

A. 3-phase induction motors - general:

1. Voltage:

a. All motors 1/2hp and larger shall be rated 460 V, 3 phase unless otherwise


b. Dual voltage motors rated 230/460 V, 3 phase are acceptable provided all leads

are brought to the conduit box.

2. Motors driving identical machines shall be identical.

3. All motors greater than 1 hp and up to 500 hp shall meet the “NEMA Premium

Efficiency” percent listed in NEMA MG-1.

4. Horsepower as indicated on the Drawings:

a. Horsepower ratings indicated on the Drawings are based on vendor’s estimates.

Provide motors sized for the load of the actual equipment furnished without

operating in the service factor.




16222 - 5

5. Service factor:

a. 1.15 service factor on sine wave power.

b. 1.0 when driven by VFD.

6. Torque:

a. Provide motors that develop sufficient torque for acceleration to full speed at

voltage 10 percent less than motor nameplate rating.

b. When started using reduced voltage starters:

1) Provide motors that develop sufficient torque for acceleration to full speed.

c. NEMA Design B except where driven load characteristics require other than

normal starting torque:

1) In no case shall starting torque or breakdown torque be less than the values

specified in NEMA MG-1.

7. Enclosures:

a. As specified in the individual equipment Specifications or in this Section.

b. Totally enclosed fan cooled:

1) Cast iron conduit box.

2) Tapped drain holes with Type 316 stainless steel plugs for frames 286 and

smaller, and automatic breather and drain devices for frames 324 and larger.

c. Explosion-proof:

1) Tapped drain holes with corrosion resistant plugs for frames 286 and smaller

and automatic breather and drain devices for frames 324 and larger.

d. Lifting devices: All motors weighing 265 pounds (120 kilograms) or more shall

have suitable lifting devices for installation and removal.

8. Manufactured with cast iron frames in accordance with NEMA MG-1 or

manufacturer’s standard material for the specified rating.

9. Nameplates:

a. Provide all motors with a permanent, stainless steel nameplate indelibly stamped

or engraved with:

1) NEMA standard motor data.

a) Indicate compliance with NEMA MG-1 Part 31 for inverter duty

motors.

2) AFBMA bearing numbers and lubrication instructions.

10. Hardware:

a. Type 316 stainless steel.

11. Conduit boxes:

a. Cast iron or stamped steel.

b. Split from top to bottom.

c. Provide gaskets at the following interfaces:

1) Frames and conduit boxes.

2) Conduit boxes and box covers.

d. Rotatable through 360 degrees in 90-degree increments.

1) Where available based on the size of the conduit box.

e. Exceeding the dimensions defined in NEMA MG-1. The main conduit box shall be

oversized at least one size larger than NEMA standard. The main conduit box




16222 - 6

shall be sized for all indicated accessory leads. Motor furnished in NEMA 320

frame series and larger shall have conduit boxes designed and constructed to

permit motor removal after installation without disconnecting raceways.

f. Provide grounding lugs inside conduit boxes for motor frame grounding.

12. Motor bearings:

a. Antifriction.

b. Oil-mist lubrication type for all applicable motors above 10 hp. Bearing mounting

shall be deigned to prevent entrance of lubricant into the motor enclosure.

c. Where oil-mist lubrication is not possible, regreasable and initially filled with

grease for horizontal motors, vertical motors per manufacturer’s standard design.

1) Provide permanently sealed bearings for motors 10 hp and below.

d. Bearings and lubrication suitable for ambient temperature and temperature rise.

e. Suitable for intended application and have ABMA L-10 rating life of 60,000 hours

or more.

f. Fit bearings with easily accessible grease supply, flush, drain, and relief fittings

using extension tubes where necessary.

g. Where specified in the equipment Specifications, provide split-sleeve type

hydrodynamic radial bearings. Provide a bearing isolator to protect bearings from

contaminants.

13. Insulation systems:

a. Motors installed in ambient temperatures 40 degrees Celsius (°C) or less:

1) Provide Class F insulation.

2) Design temperature rise consistent with Class B insulation.

3) Rated to operate at an ambient temperature of 40 °C at the altitude where

the motor will be installed.

b. Motors installed in ambient temperatures between 40 °C and 50 °C:

1) Provide Class F insulation.

2) Design temperature rise consistent with Class B insulation.


the motor will be installed.

c. Motors installed in ambient temperatures between 50 °C and 65 °C:

1) Provide Class H insulation.

2) Design temperature rise consistent with Class F insulation.


the motors will be installed.

14. Motor leads:

a. Insulated leads with non-wicking, non-hydroscopic material. Class F insulation.

b. All motors rated 100 horsepower and larger, and all vertical motors shall have

the direction of rotation marked by an arrow mounted visibly on the stator frame

near the terminal housing, or on the nameplate, and the leads marked for phase

sequence T1, T2, T3, to correspond to the direction of rotation and supply voltage

sequence. Leads for dual-voltage rated or for multispeed motors shall be easily

connected or reconnected in the main conduit box for the operating voltage or for

the specified speeds. Permanent instructions for making these connections shall

be furnished inside the main conduit box or on the motor frame or nameplate.




16222 - 7

15. Noise:

a. Maximum operating noise level in accordance with NEMA MG-1.

B. Submersible motors:

1. Enclosures:

a. Totally enclosed non-ventilated (TENV) watertight casing.

b. Inner and outer shaft seals separated by an oil chamber.

2. Cooling:

a. Suitable for continuous operation in totally, partially or non-submerged condition

without overheating.

b. Convection cooling by the surrounding environment or pump cooling by

circulating a portion of the pumped media through a cooling water jacket as

recommended by the manufacturer based on horsepower and application.

3. Electrical cables:

a. Wire unit without splices. Coordinate with Contractor to ensure cables of

adequate length.

b. Epoxy encapsulated cable entry into terminal box.

4. Insulation:

a. Sealed moisture resistant windings.

b. Class H.

5. Motor protection:

a. Provide temperature detection in motor windings.

b. Provide moisture detection in motor housing.

c. Other detection and protection functions specified in the in the driven equipment

Section.

C. Vertical motors:

1. Enclosures:

a. Totally enclosed fan cooled (TEFC) for motors 200 hp and less installed outdoors.

b. Weather protected Type II (WPII) for motors greater than 200 horsepower

installed outdoors.

c. Weather protected type I (WPI) where installed indoors.

2. Thrust bearings:

a. Selected for combined rotor and driven equipment loads.

b. Coordinate with driven equipment supplier for maximum vertical thrust of driven

equipment.

3. Anti-reverse ratchet.

D. Motors driven by variable frequency drives:

1. Compatible with the variable frequency drives specified.

2. Inverter duty rated and labeled.

3. Meet the requirements of NEMA MG-1 Part 31.

4. Winding insulation meets the requirements of NEMA MG-1 Part 31.4.4.2.




16222 - 8

5. Capable of running continuously at 1/10th of full speed, with no harmful effects of

overheating.

6. Shaft grounding ring:

a. Provide a shaft grounding ring for each VFD driven motor.

b. Aluminum frame and internal components.

c. Conductive microfiber brushes.

d. Maintenance free design.

e. Aegis Bearing Protection ring as manufactured by Electro Static Technology or

equal.

7. On motors over 100 HP, provide insulated bearings on bearings on both ends of the

motor or on the end opposite of the shaft ground ring as recommended by the motor

manufacturer.

8. In addition to the requirements of NEMA MG 1, Part 31, motors shall be designed to

be continually pulsed at the motor terminals with a voltage of 1600 volts ac.

E. Motors installed in hazardous locations: NOT USED

F. Motors installed in corrosive environments:

1. Nameplate indicating conformance to IEEE 841.

2. Stator double dipped in varnish and baked.

3. Stator and rotor coated with corrosion resistant epoxy.

4. Frame, brackets, fan guard and conduit box coated with minimum of 2 coats of epoxy

paint.

5. Withstand salt spray tests in accordance with ASTM B-117.

6. Suitable for hose down areas.

G. Single phase motors: NOT USED

H. Immersible motors: NOT USED

2.03 ACCESSORIES

A. Motor winding heaters:

1. Provide all 3 phase motors with belted or cartridge space heaters mounted within the

motor enclosure.

2. Space heater rating shall be 120 volts, single-phase, unless otherwise indicated on

the Drawings.

3. Power leads for heaters wired into conduit box.

4. Installed within motor enclosure adjacent to core iron.

B. Winding temperature detectors:

1. Provide factory installed winding temperature detector with leads terminating in the

conduit box:

a. Where required by the driven equipment Specification or as indicated on the

Drawings.

2. Temperature switches with normally closed contacts as indicated on the Drawings.




16222 - 9


A. Factory testing:

1. Motors less than 250 hp:

a. Perform manufacturer’s standard production tests including but not limited to:

1) No load current.

2) High potential test.

3) Winding resistance.

b. Furnish copies of standard test reports on prototype or identical units.

EXECUTION

3.01 INSTALLATION


B. Install motors in accordance with manufacturer's instructions.



B. Before start-up, perform insulation resistance test on each motor furnished or installed

on this project:

1. Windings energized to 1,000 volts DC for 1 minute.

2. Resistance measured at the end of the test, recorded, and submitted to the Engineer

for review.

3. Inform the Engineer of any unusual or unacceptable test results.

4. This test is in addition to the acceptance tests in Section 16950.

3.03 PROTECTION


END OF SECTION

[form follows]

MOTOR DATA SHEET

MOTOR/ EQUIPMENT TAG MOTOR NUMBER

SPECIFICATION NUMBER OF DRIVEN MACHINE

MOTOR NAMEPLATE DATA

MANUFACTURER MODEL/SERIES MODEL NO.

FRAME ENCLOSURE NEMA DESIGN

HP SERVICE FACTOR RPM

INSULATION CLASS VOLTS FULL LOAD AMPS

AMBIENT TEMP PHASE NO LOAD AMPS

DESIGN TEMP RISE HERTZ LOCK ROTOR AMPS

INRUSH CODE LETTER

100% LOAD 75% LOAD 50% LOAD

GUARANTEED MINIMUM EFFICIENCIES:

GUARANTEED MINIMUM POWER FACTOR:

MAXIMUM SIZE OF POWER FACTOR CORRECTION CAPACITOR: KVAR

ACCESSORIES

MOTOR WINDING HEATER VOLTS WATTS

WINDING THERMAL PROTECTION

WINDING TEMP SWITCHES (YES/NO)

RTD:

TYPE QUANTITY PER PHASE # OF WIRES

NOMINAL RESISTANCE NOMINAL TEMP COEFFICIENT

RECOMMENDED ALARM °C RECOMMENDED TRIP °C

SPECIAL APPLICATIONS

INVERTER DUTY* (YES/NO) PART WINDING (YES/NO) WYE - DELTA (YES/NO)

2 SPEED, 1 WINDING (YES/NO) 2 SPEED, 2 WINDING (YES/NO)

AREA CLASSIFICATION:

CLASS DIVISION GROUP TEMP CODE

* Conforms to NEMA MG-1 Part 31.

Durham AWWTF – FOG Tank Retrofit Project Variable Frequency Drives 0.50 – 50 Horsepower Part 1



16262 - 1

SECTION 16262

VARIABLE FREQUENCY DRIVES 0.50 – 50 HORSEPOWER

PART 1 GENERAL

1.01 SUMMARY


1. Variable frequency drives (VFD) 0.5 to 50 horsepower for control of NEMA Design B

squirrel cage induction motors installed in:

a. Standalone enclosures.

b. Motor control centers.

c. Vendor furnished equipment.


1. The Contract Documents are complementary; what is called for by one is as binding as

if called for by all.









b. Section 01611, Meteorological and Seismic Design Criteria.

c. Section 16050, Common Work Results for Electrical.

1.02 REFERENCES


B. Institute of Electrical and Electronics Engineers 519, IEEE Recommended Practices and

Requirements for Harmonic Control in Electrical Power Systems.

C. International Organization for Standardization (ISO):

1. 9001 - Quality Management Systems - Requirements.

D. Underwriters’ Laboratories (UL):

1. 508C - Power Conversion Equipment.

1.03 DEFINITIONS



1. Point of common coupling: the point of common coupling for all harmonic calculation

and field




16262 - 2

C. measurements for both voltage and current distortions is defined as the closest directly

connected panelboard or motor control center bus supplying power to the VFD.


A. Design requirements:

1. Each VFD system consists of all components required to meet the performance,

protection, safety, testing, and certification criteria of this Section.

B. The final VFD size shall be based on the full load current of the approved submittals of the

driven load.

1. The VFD system:

a. Is a fully integrated package.

b. Includes all material necessary to interconnect all VFD system elements, even if

shipped separately.

C. Any modifications to a standard product necessary to meet this Section shall be made

only by the VFD manufacturer:

1. Each VFD shall be completely factory pre-wired, assembled, and then tested as a

complete system by the VFD manufacturer to ensure a properly coordinated, fully

integrated drive system.

2. The VFD shall be capable of operating standard NEMA Design B motors. It is the

responsibility of the VFD manufacturer to ensure that the drive will not damage motor

insulation due to high carrier frequency, reflected wave, dv/dt or other drive electrical

characteristics based upon the installed conditions:

a. Provide equipment necessary to mitigate potential damage to motor insulation.

D. Performance:

1. Operating envelope:

a. Speed and torque requirements:

1) Provide a constant torque VFD regardless of the driven load.

2) The VFD shall be capable of producing a variable alternating

voltage/frequency output to provide continuous operation over the 40 to 200

percent (25 to 120 hertz) speed range.

b. Current requirements:

1) Full rated current output on a continuous basis.

2) Constant torque VFD:

a) Minimum 150 percent current overload for 1 minute.

b) Minimum continuous rating of 1.16% of motor nameplate full load current.

2. Minimum VFD system efficiency:

a. Ninety-six percent.

b. VFD system efficiency shall be calculated as follows: Efficiency (%) = [ Power

(Load) / Power (Supply) ] x 100

3. Power (Load) is the total power measured at the output terminals of the drive system,

including VFD, output filters or transformers. Power (Supply) is the total power

measured at the input terminals of the VFD including input filters, line reactors,




16262 - 3

isolation transformers, harmonic distortion attenuation equipment and auxiliary

equipment (e.g., controls, fans) for complete system operation.

4. Total power factor:

a. Minimum of 0.96 lagging across the entire speed range.

b. At no speed shall the VFD have a leading power factor.

5. Frequency accuracy:

a. Minimum of within 0.01 percent.

6. Speed regulation:

a. Minimum of within 0.5 percent across the entire speed range.

1.05 SUBMITTALS

A. Furnish submittals as specified in Section 01330, Submittal Procedures and

Section16050, Common Work Results for Electrical:

1. Custom prepared by the VFD manufacturer and specific for the equipment furnished.

B. Product data:

1. Manufacturer of the VFD.

2. Manufacturer of all components of the VFD.

3. Dimensions:

a. Height.

b. Width.

c. Depth.

d. Weight.

4. Nameplate schedule.

a. Provide in accordance with Section 16075, Electrical Identification.

5. Bill of material, including quantity, description, manufacturer, part number, serial

number, vendor name with phone, and spare part list with unit price. Bills of material

shall include all items within enclosure.

a. Provide the Bill of material on thumb drive in Microsoft Excel format.

6. Ratings:

a. Voltage.

b. Phase.

c. Input current.

d. Output current.

e. Interrupting rating.

f. Momentary current rating.

7. List of recommended spare parts.

8. Catalog cut sheets for major components.

9. Design data:

a. Efficiency and power factor values.

b. Certification that the drive is sized for the full nameplate motor horsepower

and current of the driven load at the installed altitude and ambient

temperature.




16262 - 4

c. Certification that based upon VFD design, cable length to motor, and motor

dielectric insulation level that the VFD will not damage motor insulation due to

carrier frequency, reflected wave, dv/dt, or other VFD produced characteristics.

d. Certification that all electronic circuits and printed circuit boards shall be

conformally coated.

10. List of diagnostic indicators.

11. List of fault and failure conditions that the drive can recognize and indicate for

simultaneous occurrence.

12. List of standard features and options.

13. For equipment installed within a motor control center, the contractor shall submit a

letter confirming each VFD unit contained within the MCC has been coordinated with

its respective driven load. Letter shall list VFD location and driven equipment tag

numbers as well as the FLA rating of each driven load motor. Motor data sheets for

each driven load motor shall be attached to the coordination letter for verification.

14. For equipment installed in structures designated as seismic design category C, D, E, or

F submit the following as specified in Section 16050, Common Work Results for

Electrical:

a. Manufacturer’s statement of seismic qualification with substantiating test data.

b. Manufacturer’s special seismic certification with substantiating test data.

15. List of parameters that will be changed from default settings.

C. Shop drawings:

1. Complete plan and elevation drawings showing:

a. All dimensions.

b. Panel, sub-panel and component layout indexed to the bill of material.

c. Conduit connections.

2. Block diagram showing the basic control and protection systems specifying the

protection, control, trip and alarm functions, the reference signals and commands and

the auxiliary devices.

3. Complete schematic, wiring and interconnection diagrams showing connections to

both internal and external devices:

a. Include terminal number and wire numbers.

4. Complete single-line and 3-line diagrams including, but not limited to, circuit breakers,

motor circuit protectors, contactors, instrument transformers, meters, relays, timers,

control devices, and other equipment comprising the complete system:

a. Clearly indicate device electrical ratings on the drawings.

D. Installation instructions:

1. Detail the complete installation of the equipment including rigging, moving, and

setting into place.

2. For equipment installed in structures designated as seismic design category A or B:

a. Provide manufacturer’s installation instructions and anchoring details for

connecting equipment to supports and structures.




16262 - 5

3. For equipment installed in structures designated as seismic design category C, D, E,

or F:

a. Provide project-specific installation instructions and anchoring details based on

support conditions and requirements to resist seismic and wind loads as specified

in Section 16050, Common Work Results for Electrical.

b. Submit anchoring drawings with supporting calculations.

c. Drawings and calculations shall be stamped by a professional engineer registered

in the state where the Project is being constructed.

E. Operation and maintenance manuals:

1. Startup and commissioning instructions and data.

2. Operating manuals:

a. Submit operating instructions and a maintenance manual presenting full details

for care and maintenance of each model of VFD provided under this Contract.

3. Operating instructions:

a. Written descriptions detailing the operational functions of all controls on the front

panel.

4. Maintenance manual:

a. Furnish maintenance manuals with instructions covering all details pertaining to

care and maintenance of all equipment as well as identifying all parts.

b. Manuals shall include, but are not limited to the following:

1) Adjustment and test instructions covering the steps involved in the initial test,

adjustment and start-up procedures.

2) Detailed control instructions which outline the purpose and operation of every

control device used in normal operation.

3) All schematic wiring and external diagrams:

a) Furnish drawings in a reduced 11-inch by 17- inch format that are fully

legible at that size.

5. List of parameters that have been changed from default settings.

F. Test reports.

G. Manufacturer’s field reports:

1. Certification letter from the VFD manufacturer that the VFD(s) has been inspected and

installed in accordance with the manufacturer’s requirements.

2. Report listing the setting of all VFD adjustable parameters and their values after start-

up.

H. Record Documents:

1. Certified Record Documents of equipment with information listed above.

1.06 SEISMIC DESIGN REQUIREMENTS

A. Provide electrical equipment with construction and anchorage to supporting structures

designed to resist site seismic loads as specified in Section 01611, Meteorological and

Seismic Design Criteria.




16262 - 6



B. Qualifications:

1. Any third party certification, safety or protection requirements shall be applied to the

VFD system as a whole. Certification or protection of system elements or individual

components by themselves is not acceptable.

2. VFD systems shall be UL 508C listed and labeled.

3. Variable frequency drives shall be manufactured by the VFD manufacturer at its own

facility which shall have a quality assurance program that is certified in conformance

with ISO 9001.


A. As specified in Section 16050, Common Work Results for Electrical and 01756 Testing,

Training and Startup.

B. Ship the VFDs and associated equipment to the job site on a dedicated air ride vehicle

that will allow the Contractor to utilize on site off-loading equipment:

1. VFDs shall be delivered to the site preassembled and wired.

2. Furnish temporary equipment heaters within the VFD to prevent condensation from

forming.


A. As specified in Section 01756, Testing, Training and Startup.

1.10 SEQUENCING

A. Refer to Section 01756, Testing, Training and Startup.

B. Following approved submittal, conduct internal factory test to ensure that all systems and

equipment are functional and submit certified test results for Engineer’s review.

1.11 SCHEDULING


1.12 WARRANTY


B. Supplier shall coordinate warranties for pumps, motors, and drives such that supplier acts

as a single point of contact for all warranties

C. OWNER shall be listed as recipient of all warranties




16262 - 7

D. At no additional charge the Manufacturer shall replace any work or material they have

provided which develops defects within 2 years from date of final acceptance of installed

equipment by OWNER.

1. Manufacturer’s service and repair support during and after warranty.

2. Correction of Defective Work: During the warranty period, SUPPLIER shall respond to

telephone notification of defective work or equipment malfunction from the OWNER by

E. dispatching a competent authorized representative to the project site within 24 hours.

SUPPLIER’s representative shall have access to all necessary parties (if necessary) within

24 hours following notification of defective work or equipment malfunction. Repairs and

adjustments involving parts shall start within 48 hours of said notification.

F. All materials and equipment shall be warranted against defective materials, design and

workmanship.

G. During the warranty period, the Manufacturer or his authorized dealer is required to make

the necessary repairs or replacements on site.

H. Warranties which mention that the part must be returned to the factory are not

acceptable.

I. During the warranty period, the Owner will not accept charges for:

1. Travel time.

2. Mileage.

3. Materials

4. On-site repair labor.

J. Warranty shall list any and all items excluded.

K. If necessary, as determined by the Owner, any repairs must be made on a premium time

basis.

1.13 SYSTEM START-UP AND COMMISSIONING


B. The VFD manufacturer shall be responsible for startup of the VFDs in the presence of the

equipment suppliers, Contractor, Engineer and Owner.

PRODUCTS

2.01 MANUFACTURERS


1. Eaton.

2. Allen-Bradley.

3. Siemens.

4. ABB.




16262 - 8

2.02 EQUIPMENT

A. General:

1. Sinusoidal pulse width modulated (PWM) type drive.

a. Six-pulse insulated gate bipolar transistor (IGBT) power section.

b. Microprocessor based controls.

c. 3% dv/dt filter and 5% load reactors.

B. Ratings:

1. Voltage:

a. Input voltage: 480 volts within 10 percent, 3-phase, 60 hertz.

C. Operational features:

1. Protective features:

a. Provide the following minimum protective features:

1) Motor overload protection.

2) Instantaneous overcurrent.

3) Instantaneous overvoltage.

4) Undervoltage.

5) Power unit overtemperature.

6) Phase loss.

7) VFD output short circuit.

2. Control mode:

a. Operation in either a constant volts/hertz or sensorless vector mode:

1) The control mode selectable using the programming keypad.

3. Frequency control:

a. Minimum of 3 selectable skip frequencies with adjustable bandwidths.

b. Programmable minimum frequency.

c. Programmable maximum frequency.

4. Acceleration/deceleration:

a. Separately adjustable acceleration and deceleration rates:

1) Each rate adjustable from 0.01 to 3,600 seconds.

5. Spinning load:

a. The VFD shall be capable of determining the speed

6. and direction of a spinning load, “catch” the load and accelerate or decelerate it

without damage to the load.

7. Programmable loss of signal:

a. Upon loss of speed reference, the VFD shall be programmable to either:

1) Stop.

2) Maintain current speed.

3) Default to pre-selected speed.




16262 - 9

8. Power interrupt ride-through:

b. The VFD shall be capable of continuous operation in the event

of a power loss of 5 cycles or less.

9. Inputs/Outputs:

a. Manufacturer’s standard number the following:

1) Analog inputs:

a) Configurable as either 0 to 10 volts or 4 to 20 milliamperes.

2) Analog outputs:

a) Programmable 4 to 20 milliamperes isolated.

3) Discrete inputs:

a) Programmable.

4) Discrete outputs:

a) Programmable.

b) Form C relay contacts.

5) Potentiometer 3-wire input.

b. Provide additional inputs/outputs as required to meet the control functions


10. Communications:

a. Provide each VFD with an Ethernet communications interface module.

11. Diagnostics:

a. Store a minimum of 4 fault conditions in non-volatile memory on a first in- first out

basis.

b. Operational parameters stored at the time of the fault:

1) Operating frequency.

2) Drive status.

3) Power mode.

c. Fault memory accessible via RS-232, RS-422 or RS-485.

12. Automatic restart:

a. User selectable automatic restart feature allowing the VFD to restart following a

momentary power failure or other VFD fault:

1) Programmable for up to 9 restart attempts.

2) Adjustable time delay between restart attempts.

2.03 COMPONENTS

A. The VFD shall be capable of being programmed while energized. Provide an accessible

port to connect a laptop from outside of the enclosure with the enclosure door closed and

the VFD energized.

B. Provide cooling devices required to maintain the VFD within the Manufacturer’s specified

temperature limits for the project conditions.




16262 - 10

C. Provide internal cooling devices and controls required to maintain the VFD within the

Manufacturer’s specified temperature limits for the project conditions.

1. Thermostat controlled air-cooling with a long-life, low noise cooling fans, sized for 100

percent capacity cooling.

2. Provide power and fuse protection for the VFD cooling fans.

3. Fans shall start when the VFD is running and shall stop when components have

cooled.

D. Power disconnect:

1. Flange mounted thermal magnetic circuit breaker.

2. Lockable in the OFF position.

E. Line Filters:

1. 3 percent input.

F. Reactors:

1. Line reactors: 5 percent output.

2.04 ENCLOSURES

A. VFDs shall be installed within motor control centers where shown on the Drawings. VFDs

not installed within MCCs shall be installed in enclosures as specified in Section 16050

Part 1.08 (C) Plant Area Electrical Work Requirement.

B. Provide louvers on the VFD enclosure, adequate in size and quantity to cool the VFD. No

filters are required.

C. Provide cooling devices required to maintain the VFD within the manufacturer’s specified

temperature limits for the Project conditions. The cooling fans shall run continuously with

VFD control power.

D. All wiring shall be MTW-type.

E. Control power transformer:

1. Furnish a control power transformer mounted and wired inside the VFD enclosure.

2. With primary and secondary fusing.

3. Sized to power all VFD controls and options as well as any external devices indicated

on the Drawings including the motor winding heater.

F. Door mounted speed potentiometer for manual speed control.

G. Keypad:

1. Provide each VFD with a keypad for programming only.

a. Control shall be through pilot devices

2. Keypad requirements:

a. Password security to protect drive parameters.

b. Mounted on the door of the motor control center.




16262 - 11

c. Back-lit LCD:

1) Minimum of 2 lines with a minimum of 16 characters per line.

d. Programming and display features language: English.

e. Capable of displaying the following parameters:

1) Speed (percent).

2) Output current (amperes).

3) Output frequency (hertz).

4) Input voltage.

5) Output voltage.

6) Total 3-phase kilowatt.

7) Kilowatt-hour meter.

8) Elapsed run time meter.

9) Revolutions per minute.

10) Direct current bus voltage.

3. In addition to all keys required for programming, provide the following controls on the

keypad:

a. Auto/manual selector.

b. Start pushbutton.

c. Stop pushbutton.

d. Jog pushbutton.

e. Speed increment.

f. Speed decrement.

g. Forward/reverse selector.

h. Run LED indicator.

i. Program LED indicator.

j. Fault LED indicator.

4. Provide the VFD with the hardwired controls as indicated on the Drawings.

5. The keypad shall be installed on the VFD enclosure door. The keypad shall be

Accessible.

6. Provide pilot devices, including but not limited to, selector switches, pushbuttons, and

indicator lights, as shown on the Drawings.

7. 22 millimeter, IEC.

8. Each pilot device shall be labeled on the front and back. Refer to the CWS Equipment

Tag Numbering Standards for additional information.

H. All conductors shall be individually labeled using heat shrinkable tube labels. Each label

shall be typewritten.

1. Conductor color coding shall be as follows:

2. Grounded conductors = White

3. Grounding conductors = Green

4. Ungrounded conductors = Red




16262 - 12

I. Provide one (1) common grounding bus bar for all grounding connections. The use of

multiple grounding bus bars shall not be accessible. The grounding bus bar shall be sized

for all grounding connections entering and leaving the enclosure.

2.05 ACCESSORIES

A. Metal oxide varistors:

1. Provide protection for the VFD against:

a. Line transients: 5,000 volt peak minimum.

b. Line to ground transients: 7,000 peak minimum.

B. Conformal coating:

1. Provide conformal coating material applied to electronic circuitry and printed circuit

boards to act as a protection

C. against moisture, dust, temperature extremes, and chemicals such as H2S and chlorine.

2.06 FINISHES

A. Enclosure finish shall be manufacturer’s standard gray.


A. VFDs and Enclosures, factory testing:

1. Control Strategies described in specification 17101 shall be reviewed and understood

by supplier prior to commencement of the Factory Test.

2. Provide a certified copy of the test results to the OWNER:

a. Include in the results any minor adjustments made during the test.

b. If major changes must be made, the test must be repeated.

3. General:

a. Incoming inspection of components and raw materials based on strategic supplier

base and experience.

b. All VFDs furnished under this Section shall be tested and inspected as specified

below. Testing of VFDs based on sampling plans is not allowed.

c. The testing procedures specified are the minimum acceptable requirements. The

manufacturer may perform additional tests at its discretion.

4. Failure of any component during testing requires repair of the faulted component and

complete retest.

5. Testing sequence:

a. Submit a detailed test procedure for the VFD factory test:

1) A minimum of 8 weeks in advance of the proposed testing date.

2) No tests shall be performed until the test procedure is reviewed and accepted

by the Engineer.

6. Component tests:

a. Preliminary inspection:

1) Verify that all components are correct.

2) Verify that all connections are properly torqued.




16262 - 13

b. Printed circuit boards:

1) Test for correct component placement and value and complete board

functional test to ensure proper performance with specified tolerances.

2) Heat cycle test for 48 hours at 60 degrees Celsius.

3) Apply control power to microprocessors, printed circuit boards, diagnostic

boards, and similar devices including software to test for proper operation,

sequencing, logic, and diagnostics.

4) Test operation of all analog and discrete inputs and outputs.

c. Wiring:

1) Control and power wiring continuity verified point-to- point.

2) Hi-pot power and control wiring at manufacturer’s recommended levels.

3) Verify ground bond resistance.

d. Load testing:

1) No load testing in accordance with the manufacturer’s standard factory test

procedure.

2) Full load testing:

a) Test each VFD and a representative motor with the system logic and a

dynamometer load to simulate field operation conditions at 25 percent,

50 percent, and 100 percent full load current.

b) Load test each VFD at a minimum ambient temperature of 40 degrees

Celsius.

(1) Monitor and record temperature rise.

(2) Once temperature rise stops continue to operate the VFD for a

minimum of 2 hours.

(a) If operating temperature exceeds the rated value, repair or replace

the VFD and retest.

EXECUTION

3.01 INSTALLATION


B. Install the equipment in accordance with the accepted installation instructions and


C. General:

1. Furnish all cables, conduit, lugs, bolts, expansion anchors, sealants, terminal block

lugs to land motor leads to, wires between VFD and terminal block lugs and other

accessories needed to complete the installation of the VFD (free-standing or within

motor control center).

2. Assemble and install the VFD in the locations and with the layouts indicated on the

Drawings.

3. Perform work in accordance with manufacturer’s instructions and shop drawings.

4. Furnish components and equipment as required to complete the installation.

5. Replace any hardware lost or damaged during the installation or handling to provide a

complete installation.




16262 - 14

6. Install free-standing enclosures on 3-1/2 inch raised concrete housekeeping pad:

a. Provide structural leveling channels in accordance with the manufacturer’s

recommendations to provide proper alignment of the units.

b. Weld and/or bolt the VFD frame to the leveling channels.

7. Provide openings in top or bottom of the VFD (free-standing or within motor control

center) enclosure for conduit only, no additional openings will be allowed:

a. Improperly cut holes will require that the entire panel be replaced:

1) No hole closers or patches will be allowed.

b. All conduits shall use threaded hubs for connections to enclosures.

8. Bundle circuits together and terminate in each unit:

a. Tie with nylon wire ties.

b. Label all wires at each end with wire numbers shown on the approved control

drawings.

c. All connections to and from the VFD (free-standing or within motor control center)

enclosure must be made via terminal blocks and wire ferrules.

9. Field wiring shall be installed so that it doesn’t block access to internal control panel

relays and devices. The relays and devices shall be accessible for testing,

maintenance, inspection, troubleshooting and replacement. The Owner shall

determine if the relays and devices are accessible and the Contractor shall move or

relocate field wiring as directed by the Owner.

10. Maintain separation of all power, signal, and control wiring within the VFD enclosure.

Verify the routing of all wiring within the VFD enclosure with the Owner prior to

installation. Move or relocate the field wiring as directed by the Owner to maintain

separation.

11. All grounding conductors shall be insulated.



B. Provide the services of a VFD manufacturer representative for startup assistance and

training:

1. Inspection and field adjustment:

a. Supervise the following and submit written certification that the equipment and

controls have been properly installed, aligned, adjusted, and readied for operation.

2. Startup field testing:

a. Provide technical direction for testing, checkout, and startup of the VFD

equipment in the field.

b. Under no circumstances are any portions of the drive system to be energized

without authorization from the manufacturer's representative.

3.03 ADJUSTING

A. Make all adjustments as necessary and recommended by the manufacturer, Engineer, or

testing firm.

1. All adjustments shall be recorded on a jump drive. The jump drive shall be provided

to the OWNER.




16262 - 15

B. Provide the services of a VFD manufacturer factory technician to make all drive

parameters and protective device settings:

1. Protective device settings provided by the VFD manufacturer in accordance with the

manufacturer of the driven equipment requirements.

2. Provide documentation of VFD settings included but not limited to:

a. Minimum speed.

b. Maximum speed.

c. Skip speeds.

d. Current limit.

e. Acceleration time.

f. Deceleration time.

g. Parameter list indicating changes from factory default settings.

3.04 CLEANING




B. The authorized representative shall instruct the OWNER's personnel in the operation and

maintenance of the equipment, including step by step troubleshooting with test

equipment for two

3.06 (2) DAYS, WITH THE FIRST HALF DAY IN CLASSROOM SETTING AND THE REST WITH ACTUAL

EQUIPMENT FURNISHED. INSTRUCTIONS SHALL BE SPECIFIC TO THE VFD MODELS

PROVIDED IN THIS PROJECT.

A. Training shall be scheduled a minimum of four (4) weeks in advance of the first session.

Training dates and time shall be determined by the OWNER. Training shall include

individual sessions for up to ten (10) personnel.

1. Proposed training materials shall be submitted for review a minimum of four

B. (4) weeks in advance, and comments shall be incorporated

C. prior to training. Training materials shall remain with the trainees. The OWNER may

videotape the training for later use with the OWNER's personnel.

3.07 PROTECTION


END OF SECTION




16052 - 1

SECTION 16411

DISCONNECT SWITCHES

GENERAL

1.01 SUMMARY


1. Fusible and non-fusible disconnect switches.


1. The Contract Documents are complementary; what is called for by one is as binding as

if called for by all.


subcontractors, suppliers, and other individuals or entities performing or furnishing any

of Contractor’s Work.

1.02 REFERENCES


B. Underwriters Laboratories Inc. (UL):

1. 20 - General-Use Snap Switches.

2. 98 - Enclosed and Dead-Front Switches.

3. 508 - Standard for Industrial Control Equipment.

C. National Electric Manufacturer’s Association (NEMA):

1. 250 - Enclosures for Electrical Equipment.

2. KS 1-2001- Enclosed and Miscellaneous Distribution Equipment Switches (600 Volts

Maximum).

1.03 DEFINITIONS



1. Safety switches and disconnect switches are to be considered synonymous.


A. Provide heavy-duty type disconnect switches as indicated on the Drawings and specified in

the Contract Documents.

B. Provide disconnect switches with the number of poles, voltage, current, short circuit, and

horsepower ratings as required by the load and the power system.

C. Provide a local horsepower rated disconnect switch as indicated on the Drawings.




16052 - 2

1.05 SUBMITTALS


B. Product data:

1. Manufacturer.

2. Manufacturer's specifications and description.

3. Ratings:

a. Voltage.

b. Current.

c. Horsepower.

d. Short circuit rating.

4. Fused or non-fused.

5. NEMA enclosure type.

6. Dimensions:

a. Height.

b. Width.

7. Depth.

8. Weight.

9. Dimensioned drawings.

10. Elementary diagrams.

11. Wiring diagrams.

12. Nameplate list.

13. Evidence that the equipment will be provided with all specified accessories, options,

features, and characteristics.

14. Certifications that the equipment is designed and manufactured in conformance with

applicable codes and standards.

C. Manual. Provide manufacturer’s installation and maintenance instruction manuals in

conformance with Section 16050, Common Work Results for Electrical.

D. Shop drawings:

1. Manufacturer's installation instructions:

a. Indicate application conditions and limitations of use stipulated by product testing

agency specified under Quality Assurance, Regulatory Requirements below.

b. Include instructions for storage, handling, protection, examination, preparation,

installation, and operation of product.

2. Identify motor or equipment served by each switch; indicate nameplate inscription.

E. Installation instructions:

1. Provide anchorage instructions and requirement based on the seismic requirements at

the Project Site as specified in Section 16050 and calculations:

a. Stamped by a professional engineer registered in the State of Oregon.




16052 - 3




1. NEMA KS1- Enclosed and Miscellaneous Distribution Switches (600 V Maximum).

2. UL 98 - Enclosed and Dead-Front Switches.

C. Disconnect switches shall be UL listed and labeled.

1.07 SEISMIC REQUIREMENTS

A. Provide electrical equipment with construction anchorage to supporting structures

designed to resist site seismic loads as specified in Section 01611, Meteorological and

Seismic Design Criteria.





1.10 WARRANTY




PRODUCTS

2.01 MANUFACTURERS

A. Disconnect Switch

1. Switch mechanism:

a. Quick-make, quick-break heavy-duty operating mechanisms:

1) Provisions for padlocking the switch in the Off position.

2) A minimum of 90-degree handle travel position between Off and On positions:

a) Provide handle position indicators to identify the handle position.

3) Full cover interlock to prevent opening of the switch door in the On position and

to prevent closing the switch mechanism with the door open:

a) With an externally operated override.




16052 - 4

2. Switch interior:

a. Switch blades visible when the switch is Off and the cover is open.

b. Lugs:

1) Front accessible.

2) Removable.

3) UL listed for 60/75-degree Celsius copper conductors.

c. Current carrying parts completely plated to resist corrosion.

d. Removable arc suppressors to facilitate easy access to line side lugs.

e. Furnish equipment ground kits for every switch.

3. Ratings:

a. UL horsepower rated for AC or DC with the rating not less than the load served.

b. Current:

1) 30 to 1,200 amperes.

c. Voltage:

1) 250 volts AC, DC.

2) 600 volts (30 A to 200 A, 600 volts DC).

d. Poles:

1) 2, 3, 4, and 6 poles.

e. UL listed short circuit ratings:

1) 10,000 RMS symmetrical amperes when used with or protected by Class H or K

fuses (30-600 amperes).

2) 200,000 RMS symmetrical amperes when used with or protected by Class R or

J fuses (30-600 amperes employing appropriate fuse rejection).

3) 200,000 RMS symmetrical amperes when used with or protected by Class L

fuses (800-1,200 amperes).

f. Where not indicated on the Drawings, provide switches with the NEMA ratings

specified in Section 16050, Common Work Results for Electrical for the installed

location.

4. Size, fusing and number poles as indicated on the Drawings or as required.

5. Local power disconnects for 480V electrical actuators shall be 3 pole, 600V, non-

fusible, NEMA 4X SS, 16 UL Amps. Power disconnect shall be ABB EOT16U3S4-P or

approved equal.

6. Auxiliary Contacts. Two sets of Form C contacts shall be provided for all disconnect

switches.

B. Motor Rated Toggle Switches

1. Switch mechanism:

a. Rotary style operating mechanism:

1) Black pistol style handle type

2) Provisions for padlocking the switch in the Off position.

3) A minimum of 90-degree handle travel position between Off and On positions:

a) Provide handle position indicators to identify the handle position.




16052 - 5

4) Full cover interlock to prevent opening of the switch door in the On position and

to prevent closing the switch mechanism with the door open:

a) With an externally operated override.

2. Switch interior:

a. Lugs:

1) Front accessible.

2) UL listed for 60/75-degree Celsius copper conductors.

b. Current carrying parts completely plated to resist corrosion.

c. Furnish equipment ground kits for every switch.

3. Ratings:

a. UL horsepower rated for AC or DC with the rating not less than the load served.

b. Current:

1) 30 amperes.

c. Voltage:

1) 250 volts, DC.

2) 600 volts, AC.

d. Poles:

1) 3 poles.

e. UL listed short circuit ratings:

1) 10,000 RMS symmetrical amperes

4. NEMA 4X stainless steel enclosure

C. Non-automatic Transfer Switch

1. General. The non-automatic transfer switch shall transfer from the normal service to an

alternate service. The transfer shall not take place automatically but shall be initiated

manually by operating personnel. Transfer back to the normal power supply shall also

be initiated manually. The switch shall be UL listed and shall bear the UL label.

2. Construction.

a. The non-automatic transfer switch shall be of the mechanically held double throw

type and connected to the transfer mechanism by a simple over-center linkage. All

main power contacts and auxiliary contacts shall be mechanically attached to a

common shaft, shall be double- break silver alloy with wiping action, and shall be

protected by arcing contacts. Arcing contacts shall close before and open after the

main contacts and shall be readily replaceable. Contact design and arrangement

shall permit repeated making and breaking of full-load current, in a combination of

motor and other loads, without damage to the main contacts. Provide a main

transfer mechanism utilizing rugged metal parts throughout. Molded circuit breaker

type designs are not acceptable.

b. The enclosure shall be NEMA 12 construction with hinged doors on the front for

access to the interior controls. Secure doors by a locking type latch. Provide two

keys for the lock.




16052 - 6

c. Cable connections shall be accessible from the front without removing internal

components.

d. Safety Requirements.

1) Arrange the electrical supply to each control panel to be disconnected by a

single switch or circuit breaker, except for necessary foreign circuits. Cover any

live parts within the control panel fed from foreign control or signal circuits or

arrange for them to be disconnected by one of the following methods:

a) Door-operated enclosed disconnect switches; or

b) Clearly identified enclosed manually operated disconnect switches, which

may be located inside the control panel door, provided the operating

handles are isolated or barriered from all open live parts.

2) Arrange the controls so that manipulation of control switches, adjustments to

timing relays, or replacement of fuses can be done without exposure to live

parts.

e. The transfer switch shall have the following features:

1) Continuous rating of 480 volts, 3-phase, with 3-poles and full neutral bus.

Current rating shall be as shown on the Drawings.

2) Adequate line and load lugs for terminating the power conductors shown on the

Drawings.

3) A terminal strip with terminals for terminating all external control circuits.

Number all terminals using the wire number for the wire terminated.

4) Cable wiring with cable ties, secured in place and guarded where subject to

mechanical injury.

5) Permanent identification of each wire at each point of connection using

numbered wiring sleeves. Provide electrically common wires with the same

number. Uniquely number electrically different wires.

3. UL Label. The transfer switch shall have a UL label on the unit when it arrives at the

site. Absence of the UL label shall be sufficient cause for the unit to be rejected.

Provide all the specified features, options, and accessories. If the manufacturer's

standard UL unit does not have the specified features, options, or accessories, then

provide alternative features, options, or accessories to accomplish the same purpose in

a manner similar to that specified, while still providing a unit with a UL label.

4. Current Ratings. The transfer switch shall have continuous ampere rating as shown on

the Drawings and a short circuit withstand rating for 3 cycles at 480 volts as follows:

Continuous Ampere

Rating

Withstand RMS Amperes,

Symmetrical

300 A 100,000

5. Finish. Shall be manufacturer's standard not less than 3 mils thick. Color shall be light

gray ANSI 61 per Z55.1.

6. Factory Tests. Assemble, wire and test the automatic transfer switch at the factory.

Conduct tests to assure that every component functions properly. Submit prototype test

reports on bus bracing for the Engineer's review.




16052 - 7

2.02 ACCESSORIES

A. Disconnect switches to have provisions for a field installable “B” type electrical interlock for

position indication as indicated on the Drawings.

B. Disconnect switches to have provisions for a field installed insulated neutral kit as


C. NEMA Type 7 and 9 enclosures furnished with drain and breather kit when used in outdoor

applications.

EXECUTION

3.01 INSTALLATION


B. Locations of disconnect switches on the Drawings are schematic in nature only.

CONTRACTOR shall install disconnects in a readily accessible location, as defined by the

NEC. All NEC working clearances shall be maintained. The CONTRACTOR shall verify the

location of all power connections for equipment requiring disconnects with the approved

Submittals and install the disconnect to meet Code.

C. Install motor rated toggle switches at gate and valve actuators.

D. Install the equipment in accordance with the accepted installation instructions and


E. General:

1. Use Myers hubs or bolt-on hubs for all conduit penetrations on NEMA Type 12, Type 4,

and Type 4X enclosures.

2. Conduits shall not enter the top of boxes in wet locations or in locations where subject

to water.

3. Provide all mounting brackets, stands, supports and hardware as required:

a. Match finish and materials for all brackets, stands, and hardware with the switch

installed.

b. Provide adequate supporting pillar(s) for disconnect switches in accordance with

the approved seismic calculations, and locate aboveground or above decks, where

there is no structural wall or surface for box.

4. When possible, mount switches rigidly to exposed building structure or equipment

structural members:

a. For NEMA Type 4 and Type 4X locations, maintain a minimum of 7/8 inch air space

between the enclosure and supporting surface.

b. When mounting on preformed channel, position channel vertically so that water

may freely run behind the enclosure.

5. Provide a nameplate for each disconnect switch:

a. Provide per requirements specified in Section 16075.

b. Identify voltage, circuit, fuse size, and equipment served on the nameplate.




16052 - 8

3.02 COMMISSIONING




3.04 CLEANING


3.05 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Lighting: LED Luminaires



16510 - 1

SECTION 16510

LIGHTING: LED LUMINAIRES

GENERAL

1.01 SUMMARY

A. Section includes: LED luminaires, drivers, poles, and accessories.


1. Section 01330, Submittal Procedures.

2. Section 01756, Testing, Training and Facility Startup.

3. Section 16050, Common Work Results for Electrical.

1.02 REFERENCES


B. Institute of Electrical and Electronics Engineers (IEEE):

1. C62.41 - IEEE Recommended Practice for Surge Voltages in Low-Voltage AC Power

Circuits.

C. Illuminating Engineering Society of North America (IESNA):

1. LM-79 - IES Approved Method for the Electrical and Photometric Measurements of

Solid-State Lighting Products.

2. LM-80 - IES Approved Method: Measuring Lumen Maintenance of LED Light Sources.

3. TM-21 - Projecting Long Term Lumen Maintenance of LED Light Sources.

D. National Electrical Manufacturers Association (NEMA):

1. 410 - Performance Testing for Lighting Controls and Switching Devices with

Electronic Drivers and Discharge Ballasts.

E. Underwriters Laboratories (UL):

1. 1598 - Luminaires.

2. 8750 - Light Emitting Diode (LED) Equipment For Use In Lighting Products.

1.03 DEFINITIONS


B. Specific definitions and abbreviations:

1. CCT: Correlated color temperature - Scientific scale to describe how “warm” or how

“cool” the light source is, measured in Kelvin. The lower the Kelvin temperature, the

warmer the light feels, or appears.

2. CRI: Color Rendering Index - A quantitative measure of the ability of a light source to

reveal the colors of various objects faithfully in comparison with an ideal or natural

light source.




16510 - 2

3. Driver - Device that manages power and controls the current flow from AC to DC for

an LED lighting product.

4. Efficacy - Lumen output of a light source per unit of power supplied to that source

(lumens per watt).

5. EMI: Electromagnetic Interference - Electrical interference (noise) generated by

electrical and electronic devices.

6. FC: Foot Candles - Measure of light level on a surface being illuminated.

7. L70 - The extrapolated life in hours of the luminaire when the luminous output

depreciates 30 percent from initial values.

8. LED: Light emitting diode - A solid-state semiconductor device that produces light

when electrical current flows through it.

9. LED light source - See LED luminaire.

10. LED luminaire - A complete lighting unit consisting of LED-based light emitting

elements and a matched driver together with parts to distribute light, to position and

protect the light emitting elements, and to connect the unit to a branch circuit.

11. Lumen - The international (SI) unit of luminous flux or quantity of light. The amount of

light that is spread over a square foot of surface by one candle power when all parts

of the surface are exactly one foot from the light source.

12. Lumen ambient temperature multiplier - LED light source relative lumen output when

compared to a standard ambient temperature.

13. Lumen maintenance factor - How well an LED light source is able to retain its

intensity when compared to new.

14. Luminaire - Lighting unit.

15. THD: Total harmonic distortion - The combined effect of harmonic Distortion on the

AC waveform produced by a driver or other device.


A. Provide luminaires, and accessories for all lighting systems, complete and operable, in

accordance with the requirements of the Contract Documents.

B. Individual luminaire types are indicated on the Drawings and on the Luminaire Schedule.

1.05 SUBMITTALS

A. Furnish submittals as specified in Section 01330, Submittal Procedures and

Section 16050, Common Work Results for Electrical.

B. Product data:

1. LED Luminaires:

a. Catalog literature for each luminaire specified, cross- referenced to the luminaire

type on the Luminaire Schedule in the Drawings.

b. Provide for each luminaire type:

1) Materials.

2) Type of diffuser.

3) Hardware.

4) Gasketing.




16510 - 3

5) Reflector.

6) Chassis.

7) Finish and color.

8) Driver type and protection.

9) LED luminaire:

a) Initial lumen output at 40 degrees Celsius ambient.

b) Correlated color temperature.

c) Lumen maintenance factors.

d) Lumen ambient temperature multipliers.

e) Drive current.

f) Efficacy.

10) Picture of luminaire.

11) Dimensioned drawings:

a) Effective projected area rating for pole mounted luminaires.

12) Weight.

13) Photometric data:

a) Coefficient of utilization tables based on the IES zonal cavity system by an

approved testing laboratory.

b) Luminaire dirt depreciation factor.

c) Candlepower distribution curves.

d) Average luminaire brightness.

e) Lumen output charts.

14) Furnish support method for interior luminaires weighing more than 30

pounds and all wall-mounted luminaires:

a) Support methods shall be based on seismic requirements at the project

site as specified in Section 16050, Common Work Results for Electrical.

c. Luminaire substitutions:

1) Provide complete literature for each luminaire substitution.

2) Submittals for substituted luminaires shall be sufficient for competent

comparison of the proposed luminaire to the originally specified luminaire:

a) Photometric data:

(1) IES file in standard IES format.

(2) Coefficient of utilization tables based on the IES zonal cavity system

by an approved testing laboratory.

(3) Candlepower distribution curves.

(4) Average luminaire brightness.

(5) Lumen output charts.

(6) Power requirements in watts and volt-amperes.




16510 - 4

b) Calculations:

(1) Provide software generated calculations showing illuminance levels in

foot candles and power usage in watts per square foot for each of the

areas in which substitutions are proposed:

(a) Use surface reflectance values and luminaire light loss factors

approved by the Engineer to perform all calculations.

c) Specification sheets:

(1) If lacking sufficient detail to indicate compliance with contract

documents, standard specification sheets will not be accepted. This

includes, but is not limited to, luminaire type designation,

manufacturer's complete catalog number, voltage, LED type, CCT,

CRI, specific driver information, system efficacy, L70 life rating, and

any modifications necessary to meet the requirements of the contract

documents.

3) Substitutions for specified luminaires will be evaluated upon quality of

construction, light distribution, energy use, appearance, and maintenance.

4) Substitutions shall comply with all applicable building and energy codes.

2. Driver: Provide for each driver type:

a. Catalog number.

b. Type of driver.

c. Output wattage.

d. Input voltage.

e. Operating voltage range.

f. Maximum input power.

g. Efficiency.

h. Operating line current.

i. Power factor.

j. Operating temperature range.

k. Current output range in ambient temperatures of 30 degrees Celsius to

55 degrees Celsius.

l. Surge suppression data.

3. Luminaire poles:

a. Submit complete data for each pole type including but not limited to:

1) Material.

2) Finish and color.

3) Handholes.

4) Anchoring.

5) Luminaire attachment methods and fittings.

6) Pole height.

7) Pole dimensions.

8) Bolt hole circle layout and hardware.

9) Accessories.

10) Provide the EPA wind load rating.




16510 - 5

C. Calculations:

1. Provide complete design calculations and installation documents for pole mounting

piers and poles mounted from structures:

a. Include in the calculations the wind and seismic requirements at the project site.

b. Calculations and design shall be performed by and signed by a Professional

Engineer registered in the state where the project is being constructed:

D. List of manufacturer recommended spare parts.

E. Record documents:

1. Update the Luminaire Schedule in the Drawings to reflect the acceptable

substitutions, after the substitution has been reviewed and accepted by the Engineer.

1.06 SPARE PARTS

A. No spare parts are required.







1.10 WARRANTY


B. LED luminaire:

1. 5 year warranty from the date of installation including material, workmanship,

photometrics, driver, and LED modules.






16510 - 6

PRODUCTS

2.01 MANUFACTURERS

A. Luminaires: One of the following or equal:

1. As noted on the Luminaire Schedule.

B. Drivers: One of the following or equal:

1. Philips Advance.

2. Thomas Research.

3. eldoLED.

C. Timer Controls: One of the following or equal:

1. Intermatic.

D. Substitutions:

1. The lighting design and luminaire selection has been based upon the photometric

data of the identified luminaire. It is the Contractor’s responsibility to ensure and

prove to the Engineer at time of submittal the substitutions meet the quality and

photometric requirements of the original design.

2.02 EQUIPMENT

A. LED Luminaires:

1. General:

a. Pre-wired with leads of 18-AWG, minimum, for connection to building circuits.

b. Provide the luminaires furnished per the Luminaire Schedule in the Drawings:

1) The Specifications noted herein are an addition or supplement to the

Luminaire Schedule.

c. Individual LEDs connected such that a catastrophic loss or the failure of 1 LED

will not result in the loss of the entire luminaire.

2. Minimum ambient temperature range of 0 degrees Celsius to 40 degrees Celsius.

3. Minimum rated life:

a. Office Areas: 70,000 hours when operated at 25 degrees Celsius.

b. Process Areas: 60,000 hours when operated at 40 degrees Celsius.

4. Minimum efficacy of 70 lumens/watt.

5. Minimum Color Rendering Index of 70.

6. Tested according to IESNA LM-79 and LM-80.

7. Lumen maintenance projection in accordance with IESNA TM-21.

8. RoHS compliant.

9. Integral driver.

10. Suitable for dry, damp, or wet locations as indicated on the Drawings or on the

Luminaire Schedule.

a. Wet or damp locations: UL 1598 listed.




16510 - 7

11. Designed as a complete LED assembly. Retrofit LED lamps in luminaires not

designed specifically for LED light sources shall not be used.

12. Exterior/outdoor luminaires:

a. Luminaires in combination with their mounting pole and bracket shall be capable

of withstanding:

1) Wind levels at the project site without damage.

2) Seismic levels at the project site.

b. Stainless steel hardware and hinged doors or lens retainer.

B. Cord and Plug Connected Luminaires:

1. All luminaires installed indoors within process areas, tunnels, electrical, and

mechanical rooms shall be cord and plug connected.

C. Timer Controls:

1. Outdoor lights shall be controlled from one astronomical timer inside the lighting

contactor located in the Electrical Room.

2. Indoor lighting shall be controlled from 2-hour timers located at the entry to each

area.

3. Where indoor light fixtures in one area are powered by multiple 120V circuits, the

lights shall be controlled from the lighting contactor located in the Electrical Room.

4. 2-hour timers shall be Intermatic FF32 or approved equal.

2.03 COMPONENTS

A. Luminaire poles:

1. As indicated on the Luminaire Schedule.

2. Anchor bolts:

a. Use anchor bolts, bolts, or welded studs for anchors for resisting seismic and

wind forces.

1) Standard hex bolt head.

2) Do not use anchor bolts fabricated from rod stock with an L or J-shape.

b. Complete with leveling shims.

3. Anchor base:

a. Fabricated from the same type of material as the pole shaft.

b. Base plate to telescope the pole shaft.

c. Welded top and bottom along the entire perimeter.

d. With slotted bolt holes on the bolt circles as submitted.

e. Base shall be hinged. The hinges shall be installed so that the pole can be laid

down in an accessible area.

4. Pole shaft:

a. As indicated on the Luminaire Schedule.

5. Handhole:

a. Reinforced handhole located approximately 18 inches above the base.

b. Complete with cover fabricated from the same material as the pole shaft and

stainless steel attachment screws.




16510 - 8

c. With an integral ground connection nut, 1/2 inch by 13 inch UNC welded to the

pole for connection to the grounding system.

d. Provide additional handhole for GFCI receptacles where shown on the Drawings.

6. Shroud:

a. Fabricated from the same type of material as the pole shaft.

7. Omni Fastening hardware:

a. All fasteners shall be stainless steel.

8. Finish:

a. As indicated on the Luminaire Schedule.

2.04 ACCESSORIES

A. Pole mounted receptacle:

1. Where indicated, furnish a 20A GFCI receptacle:

a. Integrally mounted in the pole shaft at 18 inches above the base.

b. Complete with corrosion resistant and weatherproof cover.

EXECUTION

3.01 INSTALLATION


B. Install luminaires per the manufacturer’s guidelines and submitted installation

calculations to meet seismic and wind requirements at the project site.

C. Luminaire poles:

1. Set poles on anchor bolts and secured with double nuts on each bolt.

2. Dry-pack the pole base, after the luminaire and pole has been leveled and plumbed.

3. Bond metal poles to the plant grounding system, utilizing a ground lug connection

within the pole:

a. Route ground conductor through pier and pole base sleeve using Schedule 40

PVC conduit.


A. As specified in Section 01756, Testing, Training and Facility Startup.



3.04 ADJUSTING

A. Aim and verify all exterior and outdoor luminaires alignment, during dark evening hours,

as directed by Owner or the Engineer.




16510 - 9

3.05 CLEANING


B. Clean all lenses, diffusers, and reflectors. Refinish all luminaires’ trim, poles and support

brackets, where finish has been damaged. Clean all LED luminaires (new and old), used

during construction for construction lighting, before substantial completion.

3.06 PROTECTION


3.07 SCHEDULES

A. Refer to the Luminaire Schedule in the Drawings.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Field Electrical Acceptance Tests



16950 - 1

SECTION 16950

FIELD ELECTRICAL ACCEPTANCE TESTS

GENERAL

1.01 SUMMARY


1. Responsibilities for testing the electrical installation.

2. Routine tests during installation.

3. Adjusting and calibration.

4. Acceptance tests.

5. Demonstration of electrical equipment.

6. Commissioning and plant start-up.













c. Section 16060, Grounding and Bonding.

C. Copyright information:

1. Some portions of this Section are copyrighted by the Inter National Electrical Testing

Association, Inc. (NETA). See NETA publication ATS for details.

1.02 REFERENCES


B. American National Standards Institute (ANSI).

C. ASTM International (ASTM):

1. D 877 - Standard Test Method for Dielectric Breakdown Voltage of Insulating Liquids

Using Disk Electrodes.

2. D 923 - Standard Practices for Sampling Electrical Insulating Liquids.

3. D 971 - Standard Test Method for Interfacial Tension of Oil Against Water by the Ring

Method.

4. D 1298 - Standard Test Method for Density, Relative Density, or API Gravity of Crude

Petroleum and Liquid Petroleum Products by Hydrometer Method.




16950 - 2

5. D 1500 - Standard Test Method for ASTM Color of Petroleum Products (ASTM Color

Scale).

6. D 1524 - Standard Test Method for Visual Examination of Used Electrical Insulating

Oils of Petroleum Origin in the Field.

7. D 1816 - Standard Test Method for Dielectric Breakdown Voltage of Insulating

Liquids Using VDE Electrodes.

8. D 3612 - Standard Test Method for Analysis of Gases Dissolved in Electrical

Insulating Oil by Gas Chromatography.

D. Institute of Electrical and Electronics Engineers (IEEE):

1. 43 - IEEE Recommended Practice for Testing Insulation Resistance of Rotating

Machinery.

2. 81 - IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth

Surface Potentials of a Grounding System.

3. 95 - IEEE Recommended Practice for Insulation Testing of AC Electric Machinery

(2300 V and Above) With High Direct Voltage.

4. 450 - IEEE Recommended Practice for Maintenance, Testing, and Replacement of

Vented Lead-Acid Batteries for Stationary Applications.

5. C57.13 - IEEE Standard Requirements for Instrument Transformers.

6. C57.13.1 - IEEE Guide for Field Testing of Relaying Current Transformers.

7. C57.13.3 - IEEE Guide for Grounding of Instrument Transformer Secondary Circuits

and Cases.

8. C57.104 - IEEE Guide for the Interpretation of Gases Generated in Oil-Immersed

Transformers.

E. Insulated Cable Engineer’s Association (ICEA).

F. Inter National Electrical Testing Association (NETA).

1. ATS-2009 Standard for Standard for Acceptance Testing Specifications for Electrical

Power Equipment and Systems.

G. International Electro-technical Commission (IEC).

H. Manufacturer’s testing recommendations and instruction manuals.

I. National Fire Protection Association (NFPA):

1. 70 - National Electrical Code (NEC).

2. 110 - Standard for Emergency and Standby Power Systems.

J. National Institute of Standards and Technology (NIST).

K. Specification sections for the electrical equipment being tested.

L. Shop drawings.




16950 - 3

1.03 DEFINITIONS



1. Testing laboratory: The organization performing acceptance tests.


A. Testing of all electrical equipment installed under this Contract in accordance with the

manufacturer’s requirements and as specified in this Section.

B. Conduct all tests in the presence of the Engineer or the Engineer’s representative:

1. The Engineer will witness all visual, mechanical and electrical tests and inspections.

C. The testing and inspections shall verify that the equipment is operational within the

tolerances required and expected by the manufacturer, and these Specifications. The

results of the tests shall determine the suitability for continued reliable operation.

D. Responsibilities:

1. Contractor responsibilities:

a. Ensure that all resources are made available for testing, and that all testing

requirements are met.

2. Electrical subcontractor responsibilities:

a. Perform routine tests during installation.

b. Demonstrate operation of electrical equipment.

c. Commission the electrical installation.

d. Provide the necessary services during testing, and provide these services to the

testing laboratory, Contractor, and other subcontractors, including but not limited

to:

1) Providing electrical power as required.

2) Operating of electrical equipment in conjunction with testing of other

equipment.

3) Activating and shutting down electrical circuits.

4) Making and recording electrical measurements.

5) Replacing blown fuses.

6) Installing temporary jumpers.

3. Testing laboratory responsibilities:

a. Perform all acceptance tests as defined in this Section.

b. Provide all required equipment, materials, labor, and technical support during

acceptance tests.

E. Upon completion of testing or calibration, attach a label to all serviced devices:

1. The label shall indicate the date serviced and the company that performed the

service.




16950 - 4

1.05 SUBMITTALS


B. Manufacturer’s testing procedures:

1. Submit manufacturer’s recommended testing procedures and acceptable test results

for review by the Engineer.

C. Test Report:

1. Include the following:

a. Summary of Project.

b. Description of equipment tested.

c. Description of tests performed.

d. Test results.

e. Conclusions and recommendations.

f. Competed test forms.

g. List of test equipment used and calibration dates.

D. Testing laboratory qualifications

1. Submit a complete resume and state of qualifications from the proposed testing

laboratory detailing their experiences in performing the tests specified:

a. A statement will be used to determine whether the laboratory is acceptable, and

shall include:

1) Corporate history and references.

2) Resume of individual performing test.

3) Equipment list and test calibration data.

E. Division of responsibilities:

1. Submit a list identifying who is responsible for performing each portion of the testing.



B. Testing laboratory qualifications:

1. The testing laboratory may be qualified testing personnel from the electrical

subcontractor’s staff or an independent testing company.

2. Selection of the testing laboratory and testing personnel is subject to approval by the

Engineer based on testing experience and certifications of the individuals and testing

capabilities of the organization.






16950 - 5

1.08 SEQUENCING

A. At least 30 days before commencement of the acceptance tests, submit the

manufacturer’s complete field testing procedures to the Engineer and to the testing

laboratory, complete with expected test results and tolerances for all equipment to be

tested.

B. Perform testing in the following sequence:

1. Perform routine tests as the equipment is installed including:

a. Insulation resistance tests.

b. Continuity tests.

c. Rotational tests.

2. Adjusting and preliminary calibration.

3. Acceptance tests.

4. Demonstration.

5. Commissioning and plant start-up.

1.09 WARRANTY


1.10 COMMISSIONING

A. Commissioning and plant start-up, as described in the Specifications, shall not begin

until acceptance testing is complete, and operation has been demonstrated to the

satisfaction of the Engineer.

B. Commissioning shall only be attempted as a function of normal plant operation in which

plant process flows and levels are routine and equipment operates automatically in

response to flow and level parameters or computer command, as applicable:

1. Simulation of process parameters will be considered only upon receipt of a written

request by the Contractor.

C. Record all motor currents during normal operation.

D. Record the indications of all power meters every half-hour during commissioning.

PRODUCTS


A. General:

1. Test instrument calibration:

a. Utilize a testing laboratory with a calibration program, which maintains all

applicable test instrumentation within rated accuracy.

b. The accuracy shall be traceable to the NIST in an unbroken chain.




16950 - 6

c. Calibrate instruments in accordance with the following frequency schedule:

1) Field instruments: 6 months maximum.

2) Laboratory instruments: 12 months maximum.

3) Leased specialty equipment where the accuracy is guaranteed by the lessor

(such as Doble): 12 months maximum.

d. Dated calibration labels shall be visible on all test equipment.

e. Maintain an up-to-date instrument calibration record for each test instrument:

1) The records shall show the date and results of each calibration or test.

f. Maintain an up-to-date instrument calibration instruction and procedure for each

test instrument.

EXECUTION

3.01 PREPARATION

A. Test instrument calibration:

1. Utilize a testing laboratory with a calibration program, which maintains all applicable

test instrumentation within rated accuracy.

2. The accuracy shall be traceable to the NIST in an unbroken chain.

3. Calibrate instruments in accordance with the following frequency schedule:

a. Field instruments: 6 months maximum.

b. Laboratory instruments: 12 months maximum.

c. Leased specialty equipment where the accuracy is guaranteed by the lessor

(such as Doble): 12 months maximum.

4. Dated calibration labels shall be visible on all test equipment.

5. Maintain an up-to-date instrument calibration record for each test instrument:

a. The records shall show the date and results of each calibration or test.

6. Maintain an up-to-date instrument calibration instruction and procedure for each test

instrument

B. Do not begin testing until the following conditions have been met:

1. All instruments required are available and in proper operating condition.

2. All required dispensable materials such as solvents, rags, and brushes are available.

3. All equipment handling devices such as cranes, vehicles, chain falls and other lifting

equipment are available or scheduled.

4. All instruction books, calibration curves, or other printed materials to cover the

electrical devices are available.

5. Data sheets to record all test results are available.


A. As specified in Section 01756, Testing, Training, and Facility Startup.




16950 - 7


A. Low voltage cables, 600 volt maximum:

1. Visual and mechanical inspection:

a. Compare cable data with the Drawings and Specifications.

b. Inspect exposed sections of cables for physical damage and correct connection

as indicated on the Drawings.

c. Inspect bolted electrical connections for high resistance using one of the

following methods:

1) Use of low resistance ohmmeter.

2) Verify tightness of accessible bolted electrical connections by the calibrated

torque wrench method:

a) Refer to manufacturer’s instructions for proper foot-pound levels or

NETA ATS tables.

d. Inspect compression-applied connectors for correct cable match and indentation.

e. Inspect for correct identification and arrangements.

f. Inspect jacket insulation and condition.

2. Electrical tests:

a. Perform resistance measurements through bolted connections with low-

resistance ohmmeter.

b. Perform insulation-resistance tests on each conductor with respect to ground and

adjacent conductors:

1) Applied voltage shall be:

b) 500 VDC for 300-volt rated cable.

c) 1,000 VDC for 600-volt rated cable.

2) Test duration shall be 1 minute.

c. Perform continuity tests to ensure correct cable connection.

d. Verify uniform resistance of parallel conductors.

3. Test values:

a. Compare bolted connection resistance values to values of similar connections:

1) Investigate values, which deviate from those of similar bolted connections by

more than 50 percent of the lowest value.

b. Insulation resistance values shall be in accordance with manufacturer’s

published data:

1) Refer to NETA ATS tables in the absence of manufacturer’s published data.

2) Investigate values of insulation resistance less than the allowable minimum.

c. Cables shall exhibit continuity.

d. Investigate deviations in resistance between parallel conductors.

B. Low voltage molded case and insulated case circuit breakers:


a. Compare equipment nameplate data with the Contract Documents.

b. Inspect physical and mechanical condition.

c. Inspect anchorage and alignment.




16950 - 8

d. Verify that all maintenance devices are available for servicing and operating the

breaker.

e. Verify the unit is clean.

f. Verify the arc chutes are intact.

g. Inspect moving and stationary contacts for condition and alignment.

h. Verify that primary and secondary contact wipe and other dimensions vital to

satisfactory operation of the breaker are correct.

i. Perform all mechanical operator and contact alignment tests on both the breaker

and its operating mechanism in accordance with manufacturers published data.

j. Operate circuit breaker to ensure smooth operation.

k. Inspect bolted electrical connections for high resistance by one of the following

methods:


2) Verify tightness of accessible bolted electrical connections by the calibrated


d) Refer to manufacturer’s instructions for proper foot-pound levels or

NETA ATS tables.

l. Inspect operating mechanism, contacts, and arc chutes in unsealed units.

m. Verify cell fit and element alignment.

n. Verify racking mechanism operation.

o. Verify appropriate lubrication on moving current-carrying parts and on moving

and sliding surfaces.

p. Perform adjustments for final protective device settings in accordance with the

coordination study.

q. Record as-found and as-left operation counter readings.


a. Perform resistance measurements through bolted connections with a low


b. Perform insulation resistance tests for 1 minute on each pole, phase-to-phase

and phase-to-ground with the circuit breaker closed and across each open pole:

1) Apply voltage in accordance with manufacturer’s published data.


c. Perform a contact/pole-resistance test.

d. Perform insulation-resistance tests on control wiring with respect to ground.

Applied potential shall be 500 VDC for 300-volt rated cable and 1,000 VDC for

600-volt rated cable. Apply the test voltage for 1 minute:

1) For solid state devices that cannot tolerate the applied voltage, follow the

manufacturer’s recommendation.

e. Determine the long-time pickup and delay by primary current injection.

f. Determine the short-time pickup and delay by primary current injection.

g. Determine the ground-fault pickup and delay by primary current injection.

h. Determine the instantaneous pickup value and delay by primary current

injection.

i. Test functions of the trip unit by means of secondary injection.




16950 - 9

j. Perform minimum pickup voltage tests on shunt trip and close coils in

accordance with manufacturer’s published data.

k. Verify correct operation of any auxiliary features such as trip and pickup

indicators, zone interlocking, electrical close and trip operation, trip-free,

antipump function and trip unit battery condition.

1) Reset all trip logs and indicators.

l. Verify operation of charging mechanism.

3. Test values:


1) Investigate values which deviate from those of similar bolted connections by


b. Bolted-torque levels shall be in accordance with manufacturer’s published data.


c. Insulation-resistance levels shall be in accordance with manufacturer’s published

data:


2) Investigate values of insulation-resistance less than the allowable minimum.

d. Microohm or dc millivolt drop values shall not exceed the high levels of the

normal range as indicated in the manufacturer’s published data:

1) If manufacturer’s data is not available, investigate any values which deviate

from adjacent poles or similar breakers by more than 50 percent of the

lowest value.

e. Insulation-resistance values of control wiring shall not be less than 2 megohms.

f. Long-time pickup values shall be as specified, and the trip characteristic shall not

exceed manufacturer’s published time-current characteristic tolerance band

including adjustment factors.

1) If manufacturer’s curves are not available, trip times shall not exceed the

value shown in NETA ATS tables.

g. Short-time pickup values shall be as specified, and the trip characteristic shall

not exceed manufacturer’s published time-current tolerance band.

h. Ground fault pickup values shall be as specified, and the trip characteristic shall

not exceed manufacturer’s published time-current tolerance band.

i. Instantaneous pickup values shall be as specified and within manufacturer’s

published tolerances:


j. Pickup values and trip characteristics shall be within manufacturer’s published

tolerances.

k. Minimum pickup voltage of the shunt trip and close coils shall conform to the

manufacturer’s published data:


l. Breaker open, close, trip, trip-free, antipump, and auxiliary features shall function

as designed.

m. The charging mechanism shall operate in accordance with manufacturer’s

published data.




16950 - 10

C. Grounding systems:


a. Inspect ground system for compliance with that indicated on the Drawings,

specified in Specifications, and in the National Electrical Code.


c. Inspect bolted electrical connections for high resistance using one of the

following methods:


2) Verify tightness of accessible bolted electrical connections by calibrated


e) Refer to manufacturer’s instructions for proper foot-pound levels or

NETA ATS tables.

d. Inspect anchorage.


a. Perform resistance measurements through bolted connections with a low-


b. Perform fall of potential test or alternative test in accordance with IEEE 81 on the

main grounding electrode or system.

c. Perform point-to-point tests to determine the resistance between the main

grounding system and all major electrical equipment frames, the system neutral

and any derived neutral points.

3. Test values:

a. Grounding system electrical and mechanical connections shall be free of

corrosion.

b. Compare bolted connection resistance values to values of similar connections:



c. Bolt torque levels shall be in accordance with manufacturer’s published data:


d. The resistance between the main grounding electrode and ground shall be as

specified in Section 16060. Investigate point-to-point resistance values that

exceed 0.5 ohm.

D. Variable frequency drive systems:


a. Compare equipment nameplate information with that indicated on the Drawings

and specified in the Specifications.


c. Inspect anchorage, alignment, and grounding.

d. Verify the unit is clean.

e. Ensure vent path openings are free from debris and that heat transfer surfaces

area clean.

f. Verify correct connections of circuit boards, wiring, disconnects, and ribbon

cables.




16950 - 11

g. Motor running protection:

1) Verify drive overcurrent setpoints are correct for their application.

2) If drive is used to operate multiple motors, verify individual overload element

ratings are correct for their application.

3) Apply minimum and maximum speed setpoints. Verify setpoints are within

limitations of the load coupled to the motor.

h. Inspect bolted electrical connections for high resistance using one of the

following methods:


2) Verify tightness of accessible bolted electrical connections by calibrated


f) Refer to manufacturer’s instructions for proper foot-pound levels or

NETA ATS tables.

i. Verify correct fuse sizing in accordance with manufacturer’s published data.

j. Perform visual and mechanical inspection of input circuit breaker as specified in

this Section.


a. Perform resistance measurements through bolted connections with a low


b. Test the motor overload relay elements by injecting primary current through the

overload circuit and monitoring trip time of the overload element or as

recommended by the manufacturer.

c. Test for the following parameters in accordance with relay calibration procedures

specified in this Section or as recommended by the manufacturer.

1) Input phase loss protection.

2) Input overvoltage protection.

3) Output phase rotation.

4) Overtemperature protection.

5) Direct current overvoltage protection.

6) Over frequency protection.

7) Drive overload protection.

8) Fault alarm outputs.

d. Perform continuity tests on bonding conductors as specified in this Section.

e. Perform start-up of drive in accordance with manufacturer’s published data.

Calibrate drive to the system’s minimum and maximum speed control signals.

f. Perform operational tests by initiating control devices:

1) Slowly vary drive speed between minimum and maximum. Observe motor and

load for unusual noise or vibration.

2) Verify operation of drive from remote start/stop and speed control signals.

g. Perform electrical tests of input circuit breaker as specified in this Section.




16950 - 12

3. Test values:




b. Bolt-torque levels shall be in accordance with manufacturer’s published data:


c. Overload test trip times at 300 percent of overload element rating shall be in

accordance with manufacturer’s published time-current curve.

d. Test values for input circuit breaker shall be as specified in this Section.

e. Relay calibration results shall be as specified in this Section.

f. Continuity of bonding conductors shall be as specified in this Section.

g. Control devices shall perform in accordance with system requirements.

h. Operational tests shall conform to system design requirements.

3.04 CLEANING


B. After the acceptance tests have been completed, dispose of all testing expendables,

vacuum all cabinets, and sweep clean all surrounding areas.

3.05 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Basic Measurement and Control Instrumentation



Materials and Methods

17050 - 1

SECTION 17050

BASIC MEASUREMENT AND CONTROL INSTRUMENTATION

MATERIALS AND METHODS

GENERAL

1.01 SUMMARY

A. Section Includes:

1. This Section includes general design, material, equipment fabrication, calibration,

testing, commissioning, training and documentation requirements for

instrumentation and control systems.

2. Additional or more stringent requirements, when given in other Sections, shall

prevail.

1.02 REFERENCES

A. American National Standards Institute (ANSI):

1. ANSI B16.5 - Pipe Flanges and Flanged Fittings.

B. American National Standards Institute/ American Petroleum Institute (ANSI/API):

1. API RP550 - Manual on Installation of Refinery Instruments and Control Systems.

2. ANSI/API 551-1992 - Process Measurement Instrumentation.

C. American Society of Testing and Materials (ASTM):

1. ASTM A269 - Seamless and Welded Austenitic Stainless Steel Tubing for General

Service.

D. Instrumentation, Systems, and Automation Society (ISA):

1. ISA S5.1 - Instrumentation Symbols and Identification.

2. ISA S5.3 - Graphic Symbols for Distributed Control/Shared Display Instrumentation,

Logic and Computer Systems.

3. ISA S5.4 - Instrument Loop Diagrams.

4. ISA S5.5 - Graphic Symbols for Process Displays.

5. ISA RP7.1 - Pneumatic Control Circuit Pressure Test.

6. ISA S7.3 - Quality Standard for Instrument Air.

7. ISA S12.4 - Instrument Purging for Reduction of Hazardous Area Classification.

8. ISA S18.1 - Annunciator Sequences and Specifications.

9. ISA S20 - Specification Forms for Process Measurement and Control Instruments,

Primary Elements, and Control Valves.

10. ISA S51.1 - Process Instrumentation Terminology.

11. ISA RP60.3 - Human Engineering for Control Centers.

12. ISA S71.04 - Environmental Conditions for Process Measurement and Control

Systems: Airborne Contaminants.

E. Milspec:

1. MIL-I-46058C - Electrical Insulating Compound.





17050 - 2

F. National Electrical Manufacturers Association (NEMA):

1. NEMA 250 - Enclosures for Electrical Equipment (1,000 volts maximum).

G. National Fire Protection Association (NFPA):

1. NFPA 70 - National Electric Code (NEC).

2. NFPA 496 - Purged and Pressurized Enclosures for Electrical Equipment.

3. NFPA 820 - Standard for Fire Protection in Wastewater Treatment and Collection

Facilities.

H. Scientific Apparatus Makers Association (SAMA):

1. SAMA PMC-5 - Resistance Thermometers.

2. SAMA PMC-6 - Filled System Thermometers.

3. SAMA PMC-8 - Thermocouple Thermometers.

4. SAMA PMC-17 - Bushings and Wells for Temperature Sensing Elements.

I. Underwriters Laboratories, Inc. (UL):

1. UL 508 - Industrial Control Equipment.

1.03 DEFINITIONS

A. Where a term is used in Sections 17000 through 17999 relating to instrumentation, and

the meaning is not defined therein or elsewhere in the Contract Documents, the meaning

of the term shall be as defined in ISA S51.1 Process Instrumentation Terminology, or if

not contained in ISA 51.1, as defined in listed reference standards under "References.”

B. Control Circuit:

1. Any circuit operating at 80 volts AC or DC or more, whose principal purpose is the

conveyance of information and not the conveyance of energy for the operation of an

electrically powered device.

C. PAT:

1. Performance Acceptance Test.

D. Panel:

1. An instrument support system which may be either a flat surface, a partial enclosure,

or a complete enclosure for instruments and other devices used in process control

systems. Unless otherwise specified or clearly indicated by the context, the term

"panel" in these Contract Documents shall be interpreted as a general term, which

includes flat panels, enclosures, cabinets and consoles.

E. Power Circuit:

1. Any circuit operating at 80 volts (AC or DC) or more, whose principal purpose is the

conveyance of energy for the operation of an electrically powered device.

F. PICS:

1. Process Instrumentation and Control System.





17050 - 3

G. SCADA:

1. Supervisory Control and Data Acquisition.

H. Signal Circuit:

1. Any circuit operating at less than 80 volts AC or DC.

I. Two-Wire Transmitter:

1. A transmitter, which derives its operating power supply from the signal transmission

circuit and therefore requires no separate power supply connections. As used in this

Specification, two-wire transmitter refers to a transmitter, which provides a 4 to 20

milliampere current regulation of signal in a series circuit with an external 24-volt

direct current driving potential and a maximum external circuit resistance of 600

ohms.

1.04 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION

A. Overview:

1. Instrumentation and controls for process equipment to be integrated into OWNER’s

existing PLC/SCADA system includes but is not limited to:

a. Relocated FOG waste feed pumps

b. New flow transmitters

c. New and replaced valve actuators

d. Relocated tank level transmitters

e. New FOG waste screen packaged system

f. New FOG waste offload lobe pump packaged system

2. Refer to Section 17101 for Control Descriptions.

B. Work Includes:

1. Instrumentation and control works shall include, but not be limited to, field

instrumentation and controls, integration with OWNER’s programmable logic

controller (PLC) system, control panel work, testing, training, documentation, and

related items

2. The CONTRACTOR shall provide, through the services of a qualified Process Control

and Instrumentation System (PCIS) subcontractor, a complete and functioning

control system. The PCIS shall be responsible for all control work except as excluded

in this paragraph. PLC and SCADA programming are to be provided by the OWNER.

3. Portions of this Project involve installation in existing facilities and interfaces to

existing circuits, power systems, controls, and equipment.

a. Perform and document comprehensive and detailed field investigations of

existing conditions (circuits, power systems, controls, equipment, etc) before

performing any Work.

b. Provide and document interface with, modifications to, upgrade, or replacement

of existing circuits, power systems, controls, and equipment.

c. Documentation for modified panels shall be in the form of AutoCAD drawings.

Markups of existing drawings are not acceptable. As-built drawings are available,

however, CAD drawings for existing panels are not available.

d. Only modified portions of modified panels are required to be documented.





17050 - 4

C. Work by Others:

1. The OWNER shall provide application programming for the Plant PLCs and SCADA

workstations. The CONTRACTOR shall, provide assistance with the on-site check out

of application software provided by the OWNER per Section “3.02 Field Quality

Control.”

D. Subsequently, field testing of the revised control programs shall be performed per

Section “3.02 Field Quality Control”.

1.05 DESIGN REQUIREMENTS

A. Review other Sections and Divisions of the Contract Documents for full compliance with

the total Contract Documents. In the event of a conflict between Sections, the

CONTRACTOR shall promptly seek clarification from the ENGINEER.

B. Unless different requirements are clearly specified or shown elsewhere, instrumentation

and control design, materials, equipment, installation, and testing shall comply with the

requirements of Division 16.

C. Completeness:

1. Provide a complete and fully functional instrumentation and control system ready for

use.

2. Components which are not identified on the Drawings and Specifications, but

necessary to meet the full functional operation and performance requirements, shall

be provided.

3. Equipment shall be designed and installed in full conformity with the Drawings,

Specifications, and instructions and recommendations of the related equipment

manufacturer.

D. Connections and Appurtenances:

1. The instrumentation and control systems shall include all necessary connections to

sources of electrical power, air, water, drains, and vents, with all required valves,

switches, and accessories as specified or as recommended for best operation by the

manufacturer of the equipment furnished.

2. All necessary mounting panels, stands, hangers, and brackets shall be furnished and

installed and shall comply with the relevant Sections of these Specifications.

E. Coordination:

1. Systems and equipment provided under this Section shall be designed and

coordinated for proper operation with related equipment and materials provided

under other Sections of these Specifications, and where applicable, under other

referenced contracts, and with identified existing equipment.

2. Coordinate all aspects of the Work between CONTRACTOR and all subcontractors

before bidding to ensure that all costs associated with a complete installation are

included. The OWNER is not responsible for any change orders due to lack of

coordination of the Work between the CONTRACTOR, the System Supplier, the other

subcontractors or suppliers.

F. Control Functions:

1. Control functions are provided in Section 17101, Control Descriptions.





17050 - 5

G. Instrument Tagging:

1. Attach instrument markers to all field instrument devices such as switches, and

instrument elements, sensors, transducers, control valves, etc. See “CWS

EQUIPMENT NUMBERING STANDARD” that includes an example figure and the

following list of tagging material:

a. Tag Material: SAFETYCAL FLAP TAG FT-1 Black 5”X3”

b. Label Material: Brady 2-inch-wide white (M71C-2000-595-WT or equiv.)

3 3/4 inch x 2 inch.

c. Font Size is 14 point standard except Instrument Number which is 24 point Bold.

Label text color shall be black unless instrument is used for DEQ purposes, then

text shall be red.

d. Label text will be capitalized and centered. First line of tag will be Instrument

Number. Second and if necessary third lines will be Instrument Description.

Fourth line will be Instrument Type (pH transmitter, flow transmitter, etc.) Fifth

line will be I/O address. Last line will be Power Source Location if 4-wire device or

say “Loop Powered” if 2-wire device.

e. Label will be neatly centered under laminated cover of tag with no air bubbles.

f. Install 1/4 inch grommet for stainless steel fastener.

g. Stainless Steel wire fastener

2. All back of panel instruments shall be provided with black-white-black plastic

laminate nameplates engraved with the instrument's full tag number. Nameplates

shall be secured to the panel with stainless steel screws.

3. All front of panel instruments shall include the instrument's full tag number, service

description, and (if relevant) power source in the nameplate legend. Unless it is part

of the instrument, the nameplate shall be engraved black-white-black plastic

laminate, secured with stainless steel screws.

H. (NOT USED)

I. Equipment Locations:

1. The monitoring and control system configurations are diagrammatic. The locations of

the equipment are approximate. The exact locations and routing of wiring and cables

shall be governed by structural conditions and physical interference and by the

electrical terminations on the equipment.

2. Equipment shall be located and installed so that it is readily accessible for operations

and maintenance, but does not obstruct the removal of equipment.

J. Documentation to be provided:

1. All aspects of the instrumentation and control systems design shall be fully

documented, and subsequently revised to conform to the “As-Built” installation.

2. The numbering of all instruments, equipment, terminal blocks, conductors, and

cables shall be shown on all related documents.





17050 - 6

K. Detailed Wiring Design:

1. Typical panel wiring diagrams, interconnecting wiring diagrams, and loop wiring

diagrams are included in Contract Drawings and designed to completely show control

panel wiring, terminations, interfaces with other systems, hardwire functions,

interlocks, and wiring of components provided.

2. The Contract Drawings contain typical wiring diagrams that apply to multiple circuit

diagrams, such as loop drawings and control wiring diagrams. Contractor shall

duplicate these typical drawings and customize for each control circuit and loop.

1.06 SUBMITTALS

A. General:

1. Submit in accordance with Section 01330, Submittal Procedures.

2. Submittal data shall be grouped in a logical manner to facilitate review of

subsystems and each submittal shall be substantially complete. Individual drawings

and data sheets submitted at random intervals will not be accepted for review.

3. Incomplete submittals will be returned to the CONTRACTOR without the ENGINEER's

review and without contract time extension.

4. Design Data submittals shall be reviewed and returned with resubmittal not required,

before fabrication is started.

5. All panel drawings and loop drawings shall be produced with latest version of

AutoCAD software.

6. Variations: A notice of variation shall be included in any submittal deviating from the

plans or Specifications.

7. Hardware submittals shall be provided within 60 days of the Notice to Proceed.

B. Pre-submittal Conference:

1. The ENGINEER shall arrange and conduct a Pre-submittal Conference within 60 days

after award of the Contract. The purpose of the Pre-submittal Conference is to review

and approve the manner in which the CONTRACTOR intends to carry out its

responsibilities for Shop Drawing submittal on the WORK to be provided under this

Section. The CONTRACTOR and the ENGINEER shall attend. Both the CONTRACTOR

and the ENGINEER may invite additional parties at their discretion.

2. The CONTRACTOR shall allot one, 4-hour half day for the Conference.

3. The CONTRACTOR shall present the following for discussion at the Conference:

a. A list of equipment and materials required for the PICS and the manufacturer's

name and model number for each proposed item. See Division 01300.

b. A list of proposed clarifications to the Contract Documents along with a brief

explanation of each. Resolution shall be subject to a separate formal submittal

and review by the ENGINEER.

c. An exact one-to-one sample of each type of submittal herein, including control

loop drawings as described in Project-Wide Wiring Drawing Submittal.

d. A flow chart showing the steps to be taken in preparing and coordinating each

submittal to the ENGINEER.

e. A bar-chart type schedule for all system related activities from the Pre-submittal

Conference through start-up and training. Dates of submittals, design,

fabrication, programming (by others), factory testing, deliveries, installation, field





17050 - 7

testing, and training shall be shown. The schedule shall be subdivided to show

activities relative to each major item or group of items when everything in a given

group is on the same schedule.

f. An overview of the proposed training plan. The OWNER's staff and ENGINEER will

review the overview and may request changes. All changes to the proposed

training shall be resolved at the pre-submittal conference. The overview shall

include the following for each proposed course.

1) Course title and objectives.

2) Prerequisite training and experience of attendees.

3) Course content - a topical outline.

4) Course duration.

5) Course format - lecture, laboratory demonstration, etc.

4. Provide all items to be discussed at the Pre-submittal Conference for review to the

ENGINEER and OWNER a minimum 14 days prior to the Pre-submittal Conference.

5. The ENGINEER shall take minutes of the Conference, including all events, questions,

and resolutions. Prior to adjournment, all parties must concur with the accuracy of

the minutes and sign accordingly.

C. Schedule of Values:

1. Purpose: Supplements the overall Project Schedule of Values and Progress Schedule

to provide a basis for partial payment for Work completed.

2. Content: Summary of major Milestones and associated partial payments for Work

provided under PICS Subsystems.

3. Requests for partial payment shall be considered providing:

a. Milestone activity is completed in accordance with criteria in paragraph Activity

Completion.

b. Prerequisite activities are completed in accordance with criteria in paragraph

Prerequisite Activities and Lead Times, and in conformance with Progress

Schedule.

D. Product Data:

1. General:

a. Submitted for non-custom manufactured material listed in this and other

sections and shown on shop drawings.

b. Furnish sufficient information to evaluate the suitability of the proposed material

or equipment for the intended use, and for compliance with these Specifications.

c. Include:

1) Catalog cuts.

2) Bulletins.

3) Brochures.

4) Quality photocopies of applicable pages from these documents.

5) Identify on the data sheets the project name, applicable specification section,

and paragraph.

6) Identify model number and options for the actual equipment being furnished.

d. Legibly cross out options that do not apply or equipment not intended to be

supplied.





17050 - 8

2. Material and Equipment Schedules:

a. Furnish a complete schedule and/or matrix of all materials, equipment,

apparatus, and instruments for this project.

b. Include sizes, names of manufacturers, catalog numbers, and such other

information required to identify the items.

3. Instrument Data Sheets and Cut Sheets:

a. Partially completed data sheets are provided at the end of each instrument

specification. The Contractor shall use the Specifications and Drawings to

complete the Instrument Data Sheets.

1) The partially completed data sheets are not intended to be used as a take off

list. The Contractor shall provide instruments as indicated in project

specifications and on the drawings.

b. Furnish fully completed data sheets, both electronically in Microsoft Word or

Excel and in hardcopy, for each instrument and component according to ISA S20

Specification Forms for Process Measurement and Control Instruments, Primary

Elements and Control Valves. Include the following information on the data sheet:

1) Component functional description used herein and on the Drawings.

2) Manufacturers model number or other product designation.

3) Tag number used herein and on the Drawings.

4) System or loop of which the component is a part.

5) Location or assembly at which the component is to be installed.

6) Input and output characteristics.

7) Scale range with units and multiplier.

8) Requirements for electric supply.

9) Requirements for air supply.

10) Power consumption.

11) Response timing.

12) Materials of construction and of component parts that are in contact with, or

otherwise exposed to, process media, and or corrosive ambient air.

13) Special requirements or features, such as specifications for ambient

operating conditions.

14) Features and options that are furnished.

c. Provide a technical brochure or bulletin (“cut sheet”) for each instrument on the

project. Submit with the corresponding data sheets:

1) Where the same make and model of instrument is used in 2 or more

applications on the project, and the process applications are nearly identical,

and the materials, features and options are identical submit one brochure or

bulletin for the set of identical instruments.

2) Include a list of tag numbers for which it applies with each brochure or

bulletin.

3) Furnish technical product brochures that are complete enough to verify

conformance with all Contract Document requirements, and to reflect only

those features supplied with the device.





17050 - 9

4) Cross out models, features, options, or accessories that are not being

provided.

5) Clearly mark and identify special options and features.

d. Organization: Index the data sheets and brochures in the submittal by systems or

loops.

4. Control Panel Hardware Submittal:

a. Submit the following in one submittal package.

b. Complete and detailed bills of materials:

1) A bill of material list, including quantity, description, manufacturer, part

number, serial number, vendor name with phone and spare part list with unit

price where required, shall be submitted for each of the PICS system

components. Bills of material shall include all items within an enclosure.

2) Provide the Bill of material on CD-ROM in Microsoft Excel format.

c. Complete grounding requirements for each system component including any

requirements for PLCs, process LANs, and SCADA equipment.

d. Requirements for physical separation between control system components and

120 VAC, 480 VAC, and medium voltage power cables.

e. Provide a data sheet for each control system component together with a

technical product brochure or bulletin, which include:

1) The manufacturer's model number or other identifying product designation.

2) Tag and loop number.

3) System to which it belongs.

4) Site to which it applies.

5) Input and output characteristics.

6) Requirements for electric power.

7) Requirements for air supply (if any).

8) Device ambient operating requirements.

9) Materials of construction.

10) Component functional description used in the Contract Documents.

11) Scale, range, units, and multiplier (if any).

12) Materials of component parts to be in contact with or otherwise exposed to

process media and corrosive ambient air.

13) Special requirements or features.

f. Priced list of spare parts for all devices.

E. Shop Drawings:

1. General:

a. Preparation of Shop Drawings shall not commence until adjournment of the Pre-

submittal Conference.

b. Coordinate all aspects of the Work so that a complete, instrumentation,

computer, and control system for the facility is supported by accurate shop and

record drawings:

1) Clearly show every wire, circuit, and terminal provided under this contract on

one or more submitted wiring diagrams.





17050 - 10

c. Show all interfaces between any of the following: instruments, vendor control

panels, motor control centers, motor starters, variable speed drives, control

valves, flow meters, chemical feeders and other equipment related to the PICS.

d. Generate all drawings developed for this project utilizing AutoCAD by Auto Desk:

1) Furnish on CD-ROM disks, as well as hard copies on 11-inch by 17-inch plain

bond paper.

e. Organize the shop drawing submittals for inclusion in the Operation and

Maintenance Manuals:

1) Furnish the initial shop drawing submittal bound in one or more standard

size, 3-ring, D-ring, loose leaf, vinyl plastic, hard cover binders suitable for

bookshelf storage.

2) Binder ring size: Not to exceed 3 inches.

f. Include the letterhead and/or title block of the firm responsible for the

preparation of all shop drawings. Include the following information in the title

block, as a minimum:

1) The firm's registered business name.

2) Firm's physical address, email address, and phone number.

3) OWNER’s name.

4) Project name and location.

5) Drawing name.

6) Revision level.

7) Personnel responsible for the content of the drawing.

8) Date.

2. Shop drawing requirements:

a. Front, side, and, rear elevations, and top and bottom views, showing all

dimensions.

b. Locations of conduit entrances and access plates.

c. Component layout and identification.

d. Schematic and wiring diagrams with wire numbers and terminal identification.

e. Connection diagrams, terminal diagrams, internal wiring diagrams, conductor

size, etc.

f. Anchoring method and leveling criteria, including manufacturer’s

recommendations for the seismic specified in Section 01612 and wind

conditions specified in Section 01614.

g. Weight.

h. Finish.

i. Nameplates:

1) Refer to Section 16075.

j. Temperature limitations, as applicable.

k. Interfaces between instruments, motor starters, control valves, variable speed

drives, flow meters, chemical feeders and other equipment related to the PICS

shall be included in the Shop Drawing submittal.





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3. The CONTRACTOR shall submit wiring diagrams for approval by the ENGINEER and

OWNER;

a. Wiring diagrams shall be submitted 90 days after notice to proceed. The

templates included in the contract documents will be used to document each

and every loop on the project. All control panel wiring and terminal block

numbering shall be shown, including any power wiring. After this submittal is

approved satisfactorily the control panel fabrication can proceed.

b. Preliminary field mark-up as-built wiring diagrams shall be submitted 5 days after

all equipment has successfully completed the ORT-1, ORT-2 and Performance

Tests. The wiring diagrams shall fully document any changes that have occurred

during the construction phase of the project. Final as-built wiring diagrams shall

be submitted 30 days after all equipment has successfully completed the ORT-1,

ORT-2 and Performance Testing.

4. Itemized instrument summary. The summary shall be prepared with Microsoft Excel

software and shall be submitted on hard copy. The instrument summary shall list all

of the key attributes of each instrument provided under this Contract. As a minimum,

attributes shall include:

a. Tag number.

b. Manufacturer.

c. Model number.

d. Service.

e. Area location.

f. Calibrated range.

g. Loop drawing number.

h. Associated LCP and PLC.

5. Instrument Installation Drawings:

a. Submit instrument installation, mounting, and anchoring details for all

components and assemblies in an electronic AutoCAD and hard copy format,

including access requirements and conduit connection or entry details.

b. Furnish for each instrument a dedicated 8 1/2-inch by 11-inch installation detail

that pertains to the specific instrument by tag number.

c. For each detail, provide certification and the hard copies, by the instrument

manufacturer, that the proposed installation is in accordance with the instrument

manufacturer's recommendations and is fully warrantable.

d. For each detail, provide, as a minimum, the following contents:

1) Necessary sections and elevation views required to define instrument

location by referencing tank, building or equipment names and numbers, and

geographical qualities such as north, south, east, west, basement, first floor,

etc.

2) Ambient temperature and humidity where the instrument is to be installed.

3) Corrosive qualities of the environment where the instrument is to be

installed.

4) Hazardous rating of the environment where the instrument is to be installed.

5) Process line pipe or tank size, service and material.

6) Process tap elevation and location





17050 - 12

7) Upstream and downstream straight pipe lengths between instrument

installation and pipe fittings and valves.

8) Routing of tubing and identification of supports.

9) Mounting brackets, stands, anchoring devices, and sun shades.

10) Conduit entry size, number, location, and delineation between power and

signal.

11) NEMA ratings of enclosures and all components.

12) Clearances required for instrument servicing.

13) List itemizing all manufacturer makes, model numbers, quantities, lengths

required, and materials of each item required to support the implementation

of the detail.

6. Control Panel Drawings:

a. Layout Drawings:

1) Submit panel, enclosure, console, furniture, and cabinet layout drawings for

all items provided.

2) As a minimum, include the following information:

a) To scale front, side, and plan views.

b) Dimensions.

c) Interior and exterior arrangements.

d) Mounting information, including conduit entrance location.

e) Finish data.

f) Tag number and functional name of items mounted in and on each panel,

console, and cabinet.

g) Nameplate legend including text, letter size, and colors.

b. Wiring and Piping Diagrams:

1) Submit panel wiring and piping diagrams for every panel that contains wiring

and/or piping.

2) Include the following information:

a) Name of panel.

b) Wiring and piping sizes and types.

c) Terminal strip numbers.

d) Wire tags and labels.

e) Functional name and manufacturer's designation for items to which

wiring and piping are connected.

f) Electrical control schematics in accordance with ANSI standards.

c. Installation drawings:

1) Provide site-specific installation drawings for all control equipment panels,

including dimensions.

2) Provide scaled drawings and show the position of the equipment at its

intended installation location.

3) Show the placement of all equipment being provided under this Contract and

its spatial relationship to all other equipment located in the abutting and

adjoining areas.





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4) Show all required access and clearances associated with the equipment with

a statement of compliance to manufacturer's recommendations, NEC, and

other applicable codes.

7. Control System Diagram:

a. Submit a complete set of control system diagrams including the following

information:

1) All PLCs, workstations, printers, communication devices, and communication

links:

a) Show all PLCs with their current I/O allocation, and future I/O allocation,

current plus spares provided, and maximum potential I/O based on

available slots.

2) All cables required for communication requirements.

3) Show each component fully annotated with conduit size and number

associated with the power source.

F. Testing and Startup Plan Submittal

1. Submit plan 70 days prior to start of ORT-1.

2. General testing submittal requirements are specified in this section as well as

Section 3.02. Additional requirements are specified in Section 01756 and other

Sections.

3. Testing Procedure Submittals:

a. Submit the proposed procedures to be performed during tests of the PICS and its

components in two parts:

1) Preliminary Submittal: Outline of the specific proposed tests and examples of

proposed forms and checklists.

2) Detailed Submittal: After successful review of the Preliminary Submittal,

submit the proposed detailed test procedures, forms, and checklists. Include

a statement of test objectives with the test procedures

4. The Startup Plan shall include the following:

a. Testing Plan

b. Checklist for all activities to perform during testing and startup.

c. Instrument Calibration and adjustment forms.

d. Loop and Control Circuit drawings.

e. Preliminary equipment loading sheets

f. List of all equipment included in Startup. Details include the following:

1) Associated Tag Number

2) Manufacturer Name

3) Model Number

4) Serial Number

5) Delivery Date

6) Manufacturer Warranty

g. Electrical Acceptance Sheets

1) Megger Reports

2) Continuity checks for power circuits.





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h. Certified letters of proper installation and operation by Manufacturer’s Certified

Representative.

1) The equipment and instrumentation evaluation is performed prior or during

performance of ORT-1. The list of items to be evaluated includes the

following:

i. Relocated FOG waste feed pumps

j. Relocated flow transmitters

k. New and replaced valve actuators

l. New tank level transmitters

m. New FOG waste screen packaged system

n. New FOG waste offload lobe pump packaged system

1) Acceptance of items above requires a certified copy of all test forms signed

by the, CONTRACTOR, System Supplier and the OWNER’s Representative,

with test data entered, together with a clear and unequivocal statement that

all instrumentation has been successfully calibrated, inspected, and tested.

o. Factory Acceptance Tests:

1) Include complete test procedures and forms to be used during tests.

p. Operational Readiness Test Part 1 (ORT-1):


q. Operational Readiness Test Part 2 (ORT-2):


r. Performance Acceptance Test:


2)

G. Testing Submittals:

1. Test procedures: 70 days prior to schedule start of testing.

2. Submit the following for review:

a. Factory Acceptance Test, Certified Record.

b. Operational Readiness Test Part 1 (ORT-1):

1) Preliminary Test Procedures: Outlines of proposed test, forms, and checklists.

2) Final Test Procedures: Proposed forms and checklists.

3) Test Documentation: Completed component calibration sheets with O&M

manuals.

c. Operational Readiness Test Part 2 (ORT-2):

1) Preliminary Test Procedures: Outlines of proposed forms, and checklists.

2) Final Test Procedures: Proposed forms and checklists.

d. Performance Acceptance Test:

1) Preliminary Test Procedures: Proposed tests, forms, and checklists.

2) Final Test Procedures: Proposed tests, forms, and checklists.

3) Test Documentation: Copy of signed off test procedures when tests are

completed.

e. Refer to Part 3 of this section for additional requirements.





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H. Technical Manuals/Operation and Maintenance Manuals:

1. Manuals shall be based upon the approved Shop Drawing submittals as modified for

the conditions encountered in the field.

2. Furnish the ENGINEER with a complete preliminary set of written Operation and

Maintenance Manuals 8 weeks before calibration, start-up and/or testing.

3. Furnish in accordance with Section 01782 and the following additional requirements.

4. Submit preliminary sets of these manuals to the ENGINEER for review of format and

content:

a. ENGINEER will return 1 set with comments.

b. Revise and/or amended as required and submit the requisite number of copies

to the ENGINEER 15 days before Pre-commissioning of the systems.

5. Incorporate changes that occur during startup and submit as part of the final

manuals.

6. Provide comprehensive information on all systems and components to enable

operation, service, maintenance, and repair.

7. Include Record Documents and the approved shop drawing submittals, modified for

conditions encountered in the field during the work.

8. Include signed results from Calibration, Loop Validation Tests, Pre-commissioning,

and Performance Testing.

9. Provide installation, connection, operating, calibration, setpoints (e.g., pressure,

pump control, time delays, etc.), adjustment, test, troubleshooting, maintenance, and

overhaul instructions in complete detail.

10. Provide exploded or other detailed views of all instruments, assemblies and

accessory components together with complete parts lists and ordering instructions.

11. Spare Parts List:

a. Include a priced list of recommended spare parts for all the equipment furnished

under this Contract:

1) Include recommended quantities sufficient to maintain the furnished system

for a period of 5 years.

b. Annotate the list to indicate which items, if any and quantity are furnished as part

of this Contract.

c. Provide the name, address, and phone number of manufacturer and

manufacturer's local service representative of these parts.

12. Organize the Operation and Maintenance Manuals for each process in the following

manner:

a. Section A - Process and Instrumentation Diagrams.

b. Section C - Loop Drawings.

c. Section D - Instrument Summary.

d. Section E - Instrument Data Sheets and Brochures.

e. Section F - Sizing Calculations.

f. Section G - Instrumentation Installation Details.

g. Section H - Test Results.

h. Section I - Operational Manual.

i. Section J - Spare Parts List.

j. Section K - Control and SCADA System Software.





17050 - 16

I. Training Submittals: The Training Submittal shall be based on the preliminary submittal

provided at the Pre-submittal Conference.

1. Develop and submit for review a General Training Plan. Include complete

descriptions of all planned training classes, a preliminary training schedule, a list of

all proposed instructors along with resumes, examples of proposed training manuals,

and a description of any special training tools to be used (simulators, self-paced

modules, personal computer-based training, etc.).

2. The ENGINEER will review the General Training Plan. Special emphasis will be placed

on review of the qualifications of the proposed instructors and the timing of the

individual courses to maximize their effectiveness. If, in the opinion of the ENGINEER,

the proposed instructors are not sufficiently qualified to conduct the specified

training courses, or lack experience, where required, on the specific configuration of

the system, provide more qualified instructors.

3. Training Course Plan submittals:

a. For each training course or other training activity, submit a detailed, complete

outline and agenda for each lesson.

b. Describe any student pre-requisites for the course or training activity.

c. Provide an updated schedule for all sessions of the course, including dates,

times, durations, and locations.

d. Submit training materials.

4. Incorporate all submittal review comments into the course.

5. Do not conduct training courses before review and acceptance of the Course Plan

submittal for the course.

J. Record Documents:

1. Furnish in accordance with Section 01770, Closeout Procedures.

2. Provide record documents of all instrumentation drawings.

3. Record Drawing Requirements:

a. Submit final fully updated record drawings upon completion of the Work for final

review.

b. Clearly and neatly show all changes in accordance with Section 01770, Closeout

Procedures, and the following:

1) All existing pipe, conduit, wire, instruments, or other structures encountered

or uncovered during construction.

4. Shop Drawings:

a. Upon completion of the Work, update all shop drawings to indicate the final as-

built configuration of the systems:

1) Should an error be found in a shop drawing during installation or startup of

equipment, note the correction, including any field changes found necessary,

on the drawing and submit the corrections in the Record Documents.

2) Update, check, and revise all wiring drawings and other submitted drawings

and documents to show final installed conditions.

b. Provide “As-Built” Shop Drawings for all instrumentation equipment on 11-inch by

17-inch paper.

1) Provide actual field markups (redlines) upon substantial completion.





17050 - 17

c. Provide electronic copies of these documents on CD-ROM disks in AutoCad

Version 2014 by Autodesk and .pdf. Size all Drawings to be readable and legible

on 11-inch by 17-inch media.

5. Submittal Documents:

a. Provide an interim submittal of Record Documents after the PICS system Pre-

commissioning.

b. Submit final Record Documents before Substantial Completion or earlier if so

specified in Section 01770 or the General Requirements.

6. Review and Corrections:

a. Correct any Record Documents or other documents found to be incomplete, not

accurate, of poor quality, or containing errors.

b. Promptly correct and re-submit Record Documents returned for correction.

K. Project Closeout Submittals:

1. Recommended Spare Parts List.

2. Operation and Maintenance Manuals for project, fully indexed, incorporating all

instrumentation and control system documentation submitted and produced, and

revised to conform to the “As-Built” installation. Application specific operation and

maintenance instruction and application program records shall be included. Submit 1

set for review and 4 sets of the final accepted manuals.

3. Submit reproducible Drawings revised to conform to “As-Built” installation for the

OWNER’s records after acceptance of the project Operation and Maintenance

Manuals.

4. Electronic files, 2 sets, in the form of CD-ROM disks, bearing all electronically

formatted documents including “As-Built” CAD Drawings and application programs,

shall be submitted for information only and the OWNER’s records, after acceptance

of Operation and Maintenance Manuals for project. The media shall contain a table

of contents, ASCII formatted, identifying the contents of each file and the software

program/version with which it was produced. The media shall contain a CAD plotting

document providing definition of, and correlation between layers/colors and line

types for all CAD files. A Portable Document Format (*.pdf) version of each CAD

drawing shall also be provided as part of the disk set.

5. “As-Built” Wiring Diagrams Submittals: Final “As-Built” set of wiring diagrams with

CONTRACTOR, Division 16, ELECTRICAL, and PICS supplier coordination signature

that each suppler has completed all “As-Built” markups to every detailed wiring

diagram in the construction set of wiring diagrams.


A. Procurement Restriction:

1. Certain equipment manufacturers with marketing operations based on local agents,

have terms where the selling agent has responsibility for after sales service. In such

cases, the CONTRACTOR's procurement of such equipment is restricted to the selling

agent within whose service area the equipment will be finally installed, thus assuring

the OWNER of the availability of local after sales service.





17050 - 18

B. Quality Assurance Procedure:

1. A quality assurance procedure shall be defined and implemented by the

CONTRACTOR supervising instrumentation and control systems. The procedure shall:

a. Require that the project manager schedule and budget for in-house and inter-

Contractor checking.

b. Specify qualifications required for engineering and technical personnel in the

execution and checking of specific tasks.

c. Identify the responsibilities of the executor and the checker.

d. Provide quality assurance data sheets listing specific tasks and stages of tasks,

with space for the printed names of the executor and checker, and the checker's

signature and date.

2. The quality assurance procedure shall form part of the contractual requirements for

subcontractors, and manufacturers or suppliers with unit responsibility.

3. The quality assurance data sheets shall be maintained current and shall be available

for inspection upon request.

C. Substitutes and "Or-Equals":

1. Substitutes and "Or-Equals" may be proposed in accordance with the General

Conditions.

2. Where manufacturers of instrumentation or control system products other than those

specified are proposed, they shall have a minimum of 5 years experience in the

manufacture of comparable equipment used in similar applications. The

CONTRACTOR shall provide manufacturers' references to existing installations upon

request of the ENGINEER. Noncompliance shall be a basis for rejection.

D. Coordination Meetings:

1. General: In accordance with Section 01010, Summary of Work.

a. Attendees May Include: ENGINEER, OWNER, CONTRACTOR, and PICS

Subcontractor.

b. First Meeting: Schedule per the requirements of Section 01010, Summary of

Work. Thereafter, monthly, prior to first startup activity and weekly during startup

activities. Include meetings on progress schedule.

E. Design Review Meetings:

1. CONTRACTOR shall review the system configuration, the system database, control

schemes, displays, report formats, etc. with the ENGINEER and OWNER on at least 3

occasions during development.

a. Preliminary meeting:

1) Before configuration work is begun. The ICSC must bring to this meeting

examples of displays, display symbols, reports, etc. to show the capabilities of

the system software.

b. Intermediate review meeting:

1) Held after the initial database is entered and typical screens and reports

have been entered.





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c. Final review meeting:

1) Held after initial completion of all configuration work. This final meeting may

not be held in conjunction with the FAT. Make final format revisions after this

review.

2. CONTRACTOR shall attend meetings to coordinate the SCADA system configuration,

the system database, control schemes, displays, etc., with the ENGINEER and

OWNER on at least three occasions during development.

a. Preliminary meeting:

1) Meet before configuration work is begun on any PLCs programmed by the

CONTRACTOR (including those provided through subcontractors and

suppliers). CONTRACTOR shall provide a list of each PLC and other

programmable devices that will interface to the rest of the SCADA system,

including make, model, and a description of the interface; provide contact

information for each individual responsible for programming each said PLC

and device; and provide a listing of the submittals that will contain SCADA

interface information with a schedule for when each submittal will be

provided.

b. Intermediate review meeting:

1) Held after approximately one-half of the interface submittals identified in the

Pre-submittal Conferences paragraph above have been submitted.

Individuals responsible for programming PLCs and other programmable

devices supplied by CONTRACTOR shall attend this meeting. Meet to discuss

SCADA interface submittals and requirements.

c. Final review meeting:

1) Held after all SCADA interface submittals have been submitted. Meet to

discuss SCADA interface submittals and requirements.

2) Individuals responsible for programming PLCs and other programmable

devices supplied by CONTRACTOR shall attend this meeting.


A. Storage:

1. Equipment shall not be stored outdoors. Equipment shall be stored in dry permanent

shelters, including in-line equipment, and shall be adequately protected against

mechanical injury. If any apparatus has been damaged, such damage shall be

repaired by the CONTRACTOR. If any apparatus has been subject to possible injury by

water, it shall be thoroughly dried out and put through tests as directed by the

ENGINEER. If such tests reveal defects, the equipment shall be replaced.

2. Store all equipment and materials delivered to the job site in a location that will not

interfere with the construction or the OWNER’s operations.

B. Delivery Timing:

1. No instrumentation or control system equipment shall be delivered to the job site

until required for integration with other construction, and all necessary environmental

preparations have been made.





17050 - 20

C. Intermediate Storage and Handling:

1. When the CONTRACTOR is obliged to take delivery in advance of this time, the

CONTRACTOR shall do so at a bonded air-conditioned warehouse.

2. The CONTRACTOR shall provide for storage at the warehouse and transport of the

equipment to the jobsite by suitably qualified movers with moving equipment (e.g.,

floating bed truck) as recommended by the manufacturer.

D. Non-compliance:

1. Should the equipment be delivered to the jobsite and be stored in adverse conditions

or installed in improper environmental conditions, then at the ENGINEER's discretion,

prior testing may be declared void.

2. The prior testing (e.g., factory acceptance testing) shall be repeated and/or, at the

discretion of the ENGINEER, a reduced value dollar credit shall be provided by the

CONTRACTOR.

3. The equipment shall still be required to satisfy site testing performance criteria.

1.09 SITE CONDITIONS

A. General: Instrumentation and control systems equipment shall be suitable, or made

suitable, for site conditions at the project location.

B. Temperature:

1. Electrical and Control Room Temperature: 60 to 100 degrees Fahrenheit.

2. Field Locations Temperature: 20 to 120 degrees Fahrenheit.

3. Above temperatures do not include affects of direct sunlight or wind chill.

C. Relative Humidity (RH):

1. Electrical and Control Rooms RH: 20 to 80 percent.

2. Field Locations RH: 10 to 100 percent.

D. Atmospheric Contaminants:

1. Atmospheric contaminants include hydrogen-sulfide, chlorine, ammonia and dust in

indeterminate concentrations.

2. Corrosive atmosphere testing shall be conducted, where specified.

E. Electromagnetic Radiation:

1. Electromagnetic radiation: 27 to 500 MHz: 10 volts/m.

1.10 SEQUENCING AND SCHEDULING

A. General:

1. Coordinate system delivery and installation supervision with other portions of the

Work.

B. Special Planning:

1. Retrofit of the existing plant shall be specifically scheduled and sequenced.

Shutdown of existing plant shall be minimized. All shutdown operations shall be





17050 - 21

scheduled with the OWNER. Detailed planning and careful execution shall be

conducted to limit risk of accidental shutdown of adjoining existing facilities.

2. The work shall be divided into stages that shall be individually scheduled with the

OWNER. For each stage, a detailed retrofit schedule shall be submitted. The retrofit

scheduled shall list each individual action in stop order, identifying individual devices,

terminals, and wire numbers. Prior to commencing each stage of retrofit works, and

prior to shutdown, the CONTRACTOR shall make a “dummy run” through the schedule

to add identification markers to all unmarked devices, terminals, and wires.

3. Planning or work shall include allowance for testing requirements detailed in Part 3.

PRODUCTS

2.01 MATERIALS

A. Refer to other instrumentation and control Sections.


A. Factory Testing:

1. Tests shall be observed by the OWNER. Tests may be observed by the Electrical

ENGINEER and the Project ENGINEER.

2. The OWNER shall bear costs associated with travel for this test including, but not

limited to: lodging, meals, travel time, time to witness tests, etc., for up to 3

representatives of the OWNER.

3. Costs associated with accommodation of the witness testing at the testing facility

shall be paid for by CONTRACTOR.

4. The ENGINEER shall be reimbursed by the OWNER for all costs associated with these

tests.

5. Prerequisites to Factory Testing:

a. Approved test plan.

b. Notice to the OWNER given 21 working days prior to the start of testing.

6. Instrumentation and control systems shall be factory tested and calibrated.

7. Factory test/calibration records shall be submitted to the ENGINEER to show that the

equipment has achieved the specified performance and accuracy.

8. Additional Factory Testing: Refer to other instrumentation and control Sections.

EXECUTION

3.01 INSTALLATION

A. General:

1. Install instrumentation and control systems in accordance with Drawings and

Specifications, final submittals, manufacturer’s instructions, and (where applicable)

American Petroleum Institute RP550/551.

B. Electrical:

1. Install cable and wiring in accordance with applicable Sections in Division 16.





17050 - 22

C. Piping:

1. Install piping and fittings in accordance with applicable Sections of Divisions 2 and

15.

D. Wiring Identification Numbers: Each wire shall be labeled per the Clean Water Services

standards as demonstrated on the example wiring diagrams provided as part of the

Plans and as summarized below:

1. Cable numbers shall be named based on the equipment tag of the field device

utilizing the electrical power source. The form of the tag shall be 406P1205C2 where

‘406P1205’ represents the equipment designation; ‘C’ indicated a control cable and

2 is a sequential number developed as part of the circuit design. Cable type

designations shall follow the designations listed below:

a. C - Control

b. S - Signal (below 80 volts AC or DC)

c. P - Power

d. N - Network (Ethernet, Profibus ...)

e. Examples for cable numbers:

1) Signal cable from Control Valve (406LCV1205) to PLC terminals:

a) Input twisted shielded pair:

(1) 406FCV1205S1+ and 406FCV1205S1-

b) Feedback twisted shielded pair:

(1) 406FCV1205S2+ and 406FCV1205S2-

2) Control cable to “Open” and “Closed” limit switches on control valve:

a) Power from PLC: 406ZSO1206C1

b) Return from ZSO: 406ZSO1206C2

c) Return from ZSC: 406ZSC1206C1

2. Within PLC cabinets, PLC control and signal wiring from/to I/O cards and PLC

terminal strips shall be labeled based on the rack, slot, and point number of the I/O

point. Labels shall take one of the following forms:

a. RXSYPZ - Discrete PLC I/O Wiring.

b. RXSYPZ+/- - Analog PLC I/O Wiring.

c. AC~ - Power connection.

d.

e. Where X is replaced with the PLC rack of the I/O point.

f. Where Y is replaced with the slot of the rack the I/O point is located.

g. Where Z is replaced with the point number of the slot I/O point is located.

E. Ancillary Devices: The CONTRACTOR shall be responsible for providing any additional or

different type connections as required by the instruments and specific installation

requirements. Such additions and such changes, including the proposed method of

installation, shall be submitted to the ENGINEER for approval prior to commencing the

work. Such changes shall not be a basis of claims for extra work or delay.





17050 - 23


A. Testing - General:

1. The requirements given in this Section are a minimum and may be augmented, but

not replaced, by more specific requirements in subsequent Sections.

2. As noted in Part 1 of this document, the CONTRACTOR shall submit a detailed test

plan and detailed step-by-step test procedures, complete with forms for the recording

of test results, testing equipment used, and space for signature identification of the

individual witnessing the test.

3. No required test shall be applied without prior notice to the OWNER. Testing shall not

be conducted without being witnessed unless with the prior acceptance of the

OWNER or OWNER’s representative. The Contractor shall check the installed work to

extent possible prior to formal testing to ensure that formal testing can be

expeditiously performed.

4. Each unit of test equipment used shall have a certified calibration report traceable to

the National Institute of Standards and Technology (NIST), and issued within 6

months of the testing date. These calibration reports shall be submitted with the test

records. Test instruments shall have an accuracy 3 times better than that of the

device under test. Analog devices shall be tested at 5 equally spread points over the

full range.

5. Provide onsite supervision for startup and testing activities. Provide sufficient

resources to complete all onsite testing, calibration, and adjustment during the

scheduled startup period. Provide assistance to OWNER during the startup of the

facility.

B. Operational Readiness Test (ORT): Prior to startup test period and PAT for each facility,

inspect, test, and document that the associated PICS equipment is ready for operation.

Break the ORT for each facility into two parts:

1. ORT Part 1 - Purpose: Part 1 of the ORT shall demonstrate that the installation is

physical installation is complete and the system is ready for software testing. Field

instruments shall be calibrated and receive final adjustments as part of this ORT.

Through loop tests the accuracy of all wiring shall be demonstrated; as well as,

hardwired interlocks and alarms.

2. ORT Part 1 - Prerequisites: The following activities shall be completed prior to the

start of ORT 1:

a. Electrical and equipment installation complete, including equipment tags and

wire/conduit labeling.

b. Approved wiring diagrams including loop drawings and interconnect diagrams.

c. An approved ORT 1 procedure.

d. Manufacturer approval of the mechanical installation or a confirmation that a

manufacturer’s representative will be present during the testing.

e. Notification of the Contractor’s intent to perform ORT 1 submitted 30 days prior

to the scheduled start of the ORT.





17050 - 24

3. ORT - Part 1 - Description of Test: The PICS Subcontractor shall test and document

that the Process Instrumentation and Control system, excluding OWNER provided

applications software, is ready for operation. For PICS equipment for which the

OWNER provides applications software, provide sufficient temporary software

configuration to allow testing of this equipment.

a. Loop/Component Inspections and Tests:

1) Check PICS for proper installation, calibration, and adjustment on a loop-by-

loop and component-by-component basis. Work within Division 16,

ELECTRICAL, to troubleshoot any loops that fail tests. Division 16,

ELECTRICAL, responsible for field wiring between PKS control panels and

PICS equipment.

2) Structure tests to include circuits internal to valves, MCCs and control panels.

Tests shall include vendor provided controls and equipment.

3) Provide space on forms for signoff by PICS Subcontractor.

4) Use loop status report to organize and track inspection, adjustment, and

calibration of each loop and include the following:

a) Project name.

b) Loop number.

c) Tag number for each component.

d) Check-offs/Sign-offs for each component:

(1) Tag/identification.

(2) Installation.

(3) Termination wiring.

(4) Termination tubing.

(5) Calibration/adjustment.

e) Check-offs/Sign-offs for the Loop:

(1) Panel interface terminations.

(2) I/O interface terminations with PLC’s.

f) I/O Signals for PLCs are Operational: Received/sent, processed, and

adjusted.

g) Total loop operational.

h) Space for comments.

5) Component calibration sheet for each active control system component

(except simple hand switches, lights, gauges, and similar items) and each

PLCs I/O module and include the following:

a) Project name.

b) Loop number.

c) Component tag number or I/O module number.

d) Component code number for control system elements.

e) Manufacturer for control system elements.

f) Model number/serial number for control system elements.

g) Summary of Functional Requirements, for example:

(1) Indicators and recorders, scale, and chart ranges.

(2) Transmitters/converters, input and output ranges.





17050 - 25

(3) Computing elements’ function.

(4) Switching elements, unit range, differential (fixed/adjustable), reset

(auto/manual).

(5) I/O Modules: Input or output.

h) Calibrations, for example, but not limited to:

(1) Analog Devices: Actual inputs and outputs at 0, 25, 50, 75 and 100

percent of span, rising and falling.

(2) Discrete Devices: Actual trip points and reset points.

(3) I/O Modules: Actual inputs or outputs of 0, 25, 50, 75 and 100

percent of span, rising and falling.

i) Space for comments.

6) Maintain loop status reports, valve adjustment sheets, and component

calibration sheets at site and make them available to ENGINEER at all time.

7) Full testing by PICS Subcontractor shall be completed prior to verification of

ORT-1 by ENGINEER. PICS Subcontractor to provide written confirmation of

testing completion prior to ENGINEER involvement with ORT-1 testing. These

inspections and tests will then be spot checked by ENGINEER.

8) ENGINEER reviews loop status sheets and component calibration sheets and

spot-check their entries periodically, and upon completion of ORT. Correct

deficiencies found.

b. ORT Forms: Example ORT forms referenced in Article Supplements.

4. ORT-Part 2: Combined effort between PICS Subcontractor and OWNER to confirm that

PICS, including applications software, is ready for operation.

a. ORT, Part 2 - Purpose: Each control function and operating condition shall be

tested. End-to-end loop test from field devices and equipment to the SCADA HMI

shall be performed. Test shall be performed using actual equipment and

conditions with a minimum of simulated conditions. Set points, time delay and

tuning constants shall be adjusted as part of this testing.

b. Prerequisites for ORT 2:

1) Completion of ORT-Part 1, all forms signed off by ENGINEER.

2) Approved ORT-Part 2 testing plans.

3) All equipment shall be available for operation. All manufacturer inspections

and certifications completed.

4) Testing schedule coordinated with the CONTRACTOR. Allow a minimum of two

weeks between the completion of ORT 1 and any scheduled ORT, Part 2

testing.

c. Joint test with OWNER. Plant interlocks and communication with PLC’s and

SCADA equipment tested on a loop-by-loop basis.

d. Test procedures provided by OWNER based on ORT-1 and on application software

tests.

C. Performance Acceptance Tests (PAT): These are the activities that Section 01756,

Testing, Training, and Facility Startup refers to as performance testing.

1. Once ORT has been completed and facility has been started up, perform a witnessed

PAT on complete PICS to demonstrate that it is operating as required by the Contract





17050 - 26

Documents. Demonstrate each required function on a paragraph-by-paragraph, and

loop-by-loop.

2. Loop specific and non-loop- specific tests as required for entire installed PICS tested

using actual process variables and all functions demonstrated.

3. Perform local and manual tests for each loop before proceeding to remote and

automatic modes.

4. Where possible, verify test results using visual confirmation of process equipment

and actual process variable. Unless otherwise directed, exercise and observe devices

supplied by others, as needed to verify correct signals to and from such devices and

to confirm overall system functionality. Test verification by means of disconnecting

wires or measuring signal levels is acceptable only where direct operation of plant

equipment is not possible.

5. Make updated versions of documentation required for PAT available to ENGINEER

and OWNER at site, both before and during tests.

6. Make one copy of all O&M Manuals available to ENGINEER at the site both before

and during testing.

7. Refer to referenced examples of PAT procedures and forms in Article Supplements.

D. Specialty Equipment:

1. For certain components or systems provided under this Section but not

manufactured by PICS Subcontractor, provide services of qualified manufacturer’s

representative during installation, startup, demonstration testing, and OWNER

training. Refer to Article Manufacturer’s Services in PICS Subsystems for specific

requirements.

3.03 TRAINING

A. On-Site Training:

1. Provide on-site training for all instrumentation and control systems. On-site training

shall include: testing and maintenance techniques, set up, calibration, operation,

application programming, system reconfiguration, a thorough description and

explanation of the on site control system, failure and recovery procedures (inducing

failures), and operation during failures. Both theory and hands on experience shall be

provided.

2. Allow for 40 hours of operational training with no limitation on the number of

allowable attendees.

3.04 CLEANING

A. Clean area during construction and after completion of construction.

B. Vacuum panels, cabinets, and enclosures to remove dust and debris. Wipe surfaces

clean.





17050 - 27

3.05 SUPPLEMENTS

A. Supplements listed below, following “END OF SECTION” are part of this Specification.

These forms shall be completed by the Contractor and submitted per the requirements of

this Section.

1. ORT Forms:

a. ORT-1 Form.

b. ORT-2 Form.

c. Instrument Calibration Sheet: Provides detailed information on each instrument

(except simple hand switches, lights, and similar items).

2. Performance Acceptance Test Sheet: Describes the PAT for a given loop. The format

is mostly free form.

a. Lists the requirements of the loop.

b. Briefly describes the test.

c. Cites expedited results.

d. Provides space for check-off by witness.

END OF SECTION

CWS INSTRUMENTATION CALIBRATION SHEET - SAMPLE

TRANSMITTERS AND INDICATORS

SWITCHES

Certified by:__________________________________ Date Certified:______________

Project Name: Owner Project No. (if applicable):

Project Owner: ABC Company Regulatory Agency Project No (if applicable)

Project No.: 10050-211-133 Date: 04/20/20 Control Loop No: 106

Instrument Tag No. PIT – 106A Transmitter/gauge span:

Manufacturer: ACE, Inc. Switch setpoint:

Model No.: 1275-X Switch dead band

Serial No: 3049569TSH Switch range :

Increasing Input Decreasing Input % of Span Input Output Error

(% of span) Input Output Error

0% 0.00 psi 4.02 mA 0.13 0.00 psi 4.00 mA 0.00 25% 50.00 psi 8.00 mA 0.00 50.00 psi 8.01 mA 0.06 50% 100.00 psi 12.01 mA 0.06 100.00 psi 12.00 mA 0.00 75% 150.00 psi 16.00 mA 0.00 150.00 psi 16.01 mA 0.06 100% 200.00 psi 20.00 mA 0.00 200.00 psi 19.99 mA 0.06 Other (if applicable) Other (if applicable)

Maximum allowable error (per Contact Documents): 0.15% Span

Remarks: Adjusted zero- otherwise no adjustments required.

Actuation point Increasing Input Decreasing Input

Input Output Error Input Output Error (% of span)

High (increasing input) Low (increasing input)

Forest Grove WWTF – Clarifier ProjectEngineer Project Number: 152766 17050-SUP1Owner Project Number: 6925

SOLIDS BLDG ODOR CONTROLPN 6755

Loop No. Tag No. Device Description Cal. Sheet P & ID Panel Wiring Diagram Checked750TIT5031 Temperature Ind. Xmtr750DPSL5033 Pressure Diff. Switch Low

Loop No. Tag No. Loop Description High Range PLC Rack Slot Point Type P & ID Panel Wiring Diagram I/O Checked750TIT5031750DPSL5033

Loop No. Wire No. Loop Description Field Device PLC Terminal No. PLC Panel Wiring Diagram Checked750TIT5031 750TIT5031S1+ XXX TEMPERTURE 750LCPXXX

750TIT5031S1- XXX TEMPERTURE750DPSL5033 750DPSL5033S1+ XXX PRESSURE XXXX

750DPSL5033S1- XXX PRESSURE XXXX

ORT - Part 1: Test Procedures1. Verify component tag/identification.2. Verify correct wire terminations and instrument installation.3. Instrument calibrations completed. (Fill out calibration sheet for each instrument)4. Verify I/O signals to/from PLC, using the actual field devices when possible. (limit switch, hand switch, etc.)5. Verify loop is ready for operation.

ORT - Part 1 Loop Testing Completed:__________________________________ Date:_______________(Integrator - Company Name) System:

ORT - Part 1 Loop Testing Completed:__________________________________ Date:_______________(Electrical Contractor - Company Name)

Operational Readiness Testing (ORT - Part 1)Instruments & Interface Devices

Status or Range

PLC I/O

Field WiringField Term. No.

1 TB1-352 TB1-38

Loop Checkout Comments/Notes/Problems

Clean Water ServicesDurham Odor control, PN 6755

17050 Sup-2 -1 -

Operational Readiness Testing (ORT - Part 1)November 9, 2015

SOLIDS BUILDINGPN 6755

Example - Operational Readiness Testing (ORT - Part 2)

Loop No. Tag No. Device Description Cal. Sheet P & ID Wiring Diagram PanelBasin No. 7 Zones 1 & 2 Primary Effluent Flow meter I-6 P74-L400FIT1501

Loop No. Tag No. Loop Description High Range PLC Rack Slot Point Type P & ID Wiring Diagram Panel400FIT1501 WX2013 Basin No. 7 Zones 1 & 2 Primary Effluent Flow 10,000 = 20mA 3 9 8 5 AI I-6 P74-L400FIT1501 40LP01400FY1501 WY2002 Basin No. 7 Zones 1 Flow Control Valve 100% = 20mA 3 9 12 2 AO I-6 P74-L400FIT1501 40LP01400FY1517 WY2001 Basin No. 7 Zones 2 Flow Control Valve 100% = 20mA 3 9 12 1 AO I-6 P74-L400FIT1501 40LP01

Manual See # 1 Command 0% 50% 100% 50% 0%Valve PositionLoop PVMeter Display

Auto See # 4 Increase SPDecrease SP

LEVEL Basin High Level DesignActual

Basin Low Level DesignActual

ORT - Part 2: Test Procedures1. Place devices in Remote & SCADA Manual. Verify SCADA Manual Control (0-50-100-50-0%), Record Valve response and Loop PV (if possible)2. Verify correct loop response during manual actuation.3. Verify SCADA loop response matches device within tolerence.4. Place loop in Auto mode(s), verify loop control responds correctly to SP and PV changes.5. Verify loop is ready for operation.

ORT - Part 2 Loop Testing Completed:___________________________________ Date:_______________ System:(Integrator - Company Name)

ORT - Part 2 Loop Testing Completed:___________________________________ Date:_______________Second Verification-Electrical Contractor

Loop Checkout Comments/Notes/Problems

Instruments & Interface DevicesStatus or Range

400FE/FIT1501 0-10,000 GPM = 4-20mADC

PLC I/O

Tests

Trip Reset Units

Clean Water ServicesRock Creek MCC-G Replacement ProjectCWS Contract No.

17050 Sup-3 - 1 -

Example - Operational Readiness Testing (ORT - Part 2)October 2011

Forest Grove WWTF – Clarifier Project Engineer Project Number: 152766 Owner Project Number: 6925

17050 - SUP4

PERFORMANCE ACCEPTANCE TEST SHEET -EXAMPLE-

Project Name: MCC-G Replacement Project

Project No.: 7182E10 300

Demonstration test(s): For reach functional requirement of the loop: (a) List and number the requirement; (b) Briefly describe the purpose and steps for each test; (c) Record results; (d) Sign off.

1. Pump No. 1 Verification - SCADA Manual Mode.

1a. Activate Pump No. 1 via SCADA terminal

1b. Verify pump starts and speed is reported to SCADA.

1c. Adjust pump speed through full range.

1d. Verify the VFD ramp rate is properly set. (xx% per second)

1e. Verify speed reported properly locally and at SCADA

1f. Simulate a moisture alarm in the pump. Verify the alarm is sent to SCADA and the pump continues to run.

1g. Simulate a motor winding temperature alarm in the pump. Verify the alarm is sent to SCADA and the pump shutdown sequence is initiated.

1h. Reset the pump and simulate a high wet well level. Verify the pump starts in backup mode and pumps the wet well level down to the low level cutout, then stops.

1i. Verify normal operation is resumed after the pump is stopped in backup mode.

Forms/Sheets Verified By Date Owner Sign-Off

Loop Drawings/ORT Results

Instrument Calibration Sheets

Performance Acceptance Test By Date

Performed

Witnessed Loop No.:

Durham AWWTF – FOG Tank Retrofit Project Control Loop Descriptions



17101 - 1

SECTION 17101

CONTROL LOOP DESCRIPTIONS

GENERAL

1.01 DESCRIPTION

A. This section includes the Control Loop Descriptions that follow the end of this section.

1. D60-110-CTL-100 FOG Waste Storage and Feed

2. D60-110-CTL-110 Digester FOG Feed

3. D60-130-CTL-010 FOG Waste Receive and Recirculation

4. D60-170-CTL-130 Heating Loads FOG Waste Receiving

5. Xxx-xxx-CTL-xxx Temporary FOG Waste Receive, Recirculation, Storage and Digester

FOG Feed

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Control Loop Description 1 Engineer Project Number: 154061 Owner Project Number: 6992

Control Loop Description FOG Waste Storage and Feed

Process Description:

FOG is stored in two tanks. In normal operations, inter-tank isolation valve FV-6409 is open

such that the tanks are hydraulically coupled. For operation in SPLIT mode or for taking a

tank out of service, FV-6409 is closed. SPLIT mode can be enabled when there is low FOG

inventory. The inter-tank isolation valve is provided so each tank can be accessed for

maintenance. Level is measured and FOG Waste Transfer Pumps and FOG Feed Pumps are

shut off when associated tank level falls below the minimum low-liquid level.

The vents from the tanks are routed to a passive odor control system. This system contains

two passive activated carbon barrels, one per tank, located on the backside of the building.

Feed to the digesters is provided by variable speed progressing cavity pumps with a range of

approximately 5 to 50 gpm. Flow rate setpoint is entered by operator based on experience. An

operator-initiated flushing system using heated plant non-potable water is available to

periodically clean the digester feed pipes.

Two FOG waste pipes from the feed pumps to the digesters provide redundancy should one

of the pipes become clogged, except when operating in SPLIT mode, in which case each pipe

is dedicated to a digester.

FOG Feed flow meters 750FIT6402 and 715FIT6404 are located in the lower level of DC-2.

There are two SCADA AUTO modes: SCADA AUTO – FLOW and SCADA AUTO –

BUBBLE.

SCADA AUTO – FLOW:

Each digester is fed FOG continuously and the flowrate is a simple operator set point. Care

should be taken when selecting a set point to prevent overloading of FOG into the digesters

and to ration FOG so it does not run out before the next delivery. Flowrates are usually

between 5-10 gpm.

SCADA AUTO – BUBBLE:

The digester FOG flowrate is adjusted based on a direct feedback loop. The system will look

at the digester gas bubble storage and adjust the flowrate up or down as necessary to maintain

85%-90% full. This will help maximize gas production as the engines will be running at full

capacity and flaring will be unnecessary. When a FOG tank level reaches a designated low

level (operator adjustable), the FOG feed rate will be dropped to a designated low flowrate to

ensure that there is enough FOG until the next delivery. Initially this is set to be XX gallons

to be consumed over XX days. The digesters remain more stable when FOG is delivered

consistently.

Materials of construction and instrumentation are capable of operating at elevated

temperatures up to 150 degrees F.


FOG volume below EL171.50 of FOG storage tanks are not accessible by the feed pumps due

cone-bottom configuration. Pumps generally pull from Tank #1 to utilize the lower suction

line.

Last Update: May 22, 2020 Approved By:

Equipment

Unit Equipment:

Equipment Name Tag Number Type Rating

FOG Feed Pump No. 1 715P6402 Progressing

Cavity 2 - 50 gpm


Cavity 2 - 50 gpm

Digester Gas Storage Tank 740T6901 Dual-

Membrane

Instrumentation

Instrument Name Tag Number Type Range

FOG Waste Receiving Tank 1 Level

Transmitter 715LIT6401 Radar 0 – 25 feet

FOG Waste Feed Pump 1 Discharge

Pressure Switch 715PSH6402 50 psig

FOG Waste Feed Pump 1 Stator

Temperature Switch 715TSH6402


Flow Meter 750FIT6402 Electromagnetic 0 – 50 gpm









Gas Storage Tank Gas Level

Transmitter 740LIT6901 Laser 0-100%

Control Strategies

A. Local Control Operation and Alarm Reset:

1. Manufacturer-Supplied Control Panels: N/A


2. MFR Control Center: None.

3. Local Control Station:

a. Shutdown interlocks for each Feed Pump:

i. Pump Stator Temperature HIGH.

ii. Pump Discharge Pressure HIGH.

b. For Feed Pumps:

i. LOCAL-OFF/RESET-REMOTE selector switch.

ii. START and STOP pushbuttons for LOCAL control.

iii. REMOTE control from SCADA

4. Intermediate Control Panel: N/A

B. SCADA Control Operation and Alarm Reset:

1. SCADA Manual: For each Pump:

a. Place the equipment LOCAL-REMOTE selector in REMOTE.

b. Place the MANUAL-AUTO selector at the HMI graphics in MANUAL.

c. Press the HMI START button to start the equipment.

d. Press the HMI STOP button to stop the equipment.

2. SCADA Auto:

Flow mode:

a. The FOG Feed Pumps operate continuously. FOG Feed pump speed is

controlled to maintain an operator-entered flow setpoint.

b. Stop pump if associated tank is below low-low level shutoff

a. Tank #1: EL171.875

b. Tank #2: EL171.875

c. Prior to starting a FOG Feed pump, open the suction side flush solenoid for a

preset time (0 to 30 seconds). This will flush the tank sump area.

Bubble Mode:

a. The FOG Feed Pumps operate continuously. A direct feedback loop will

increase or decrease the FOG pump speed to keep the gas bubble 85-90%.

b. There is a tank level setpoint for minimum flow. When the FOG tanks reach this

point, they will revert to the low flow setpoint in order to conserve FOG.

a. Typical low flow setpoint will be 5 gpm

b. Typical low tank level setpoint for low flow will be EL171.875

c. Stop pump if associated tank is below low-low level shutoff

a. Tank #1 EL171.875

b. Tank #2 EL171.875

SCADA Display

A. Status and Process Display:

1. For each Pump:

a. ON status.

b. REMOTE mode.

c. Flush valve OPEN.

d. Speed.

e. Flow rate and total.


B. Operator Entries:

1. For each Pump:

a. SCADA MANUAL/AUTO selection.

b. MANUAL START/STOP control.

2. BUBBLE or FLOW mode selection

3. For each pump:

a. FOG Feed flow setpoint. (FLOW mode)

b. FOG max/min flowrate (BUBBLE mode)

c. Controlling level transmitter selection (reflects manual valve setup for pump

suction)

4. For each Tank:

a. Tank level setpoint for minimum flow (BUBBLE mode)

5. Pre-flush solenoid time setting.

6. Duty pump selection 1/ALT/SPLIT/2.

C. SCADA Historical Trending:

1. For each Tank:

a. Level.

2. For each Pump:

a. Flow rate.

b. Pump Speed.

3. Quick trend:

a. Gas Bubble Level and FOG Flow and GT3 underflow pump speed and sum of

gas use (engine ½ and flare ½ and boilers)

SCADA Alarms and Interlocks

A. Alarms:

1. For each Pump:

a. FAIL alarm.

b. FAIL to Start and FAIL to Stop alarms.

c. LOW flow when the flow is less than 2 gpm for 60 seconds while the pump is

running.

d. HIGH discharge pressure.

e. HIGH stator temperature.

f. FOG Tank Low Level

B. Hard-Wired Interlocks:

1. Shutdown interlocks for each Feed Pump:

a. Pump Stator Temperature HIGH.

b. Pump Discharge Pressure HIGH.

C. Software Interlocks:

1. Interlock each Pump with LOW-LOW level in associated Tank (EL171.875); stop

Pump below LOW-LOW level.

2. Interlock each Pump with READY signal from DC2.

Programming Requirements

A. Equipment Run Time Counters: Run Time for each Pump.

B. Equipment Failure Sequence: None.

C. Equipment Automatic Failover Sequence: None.


END OF DOCUMENT


Control Loop Description Temporary FOG Waste Storage and Feed


FOG is stored in two temporary tanks that are hydraulically coupled. Level is measured and

FOG Waste Transfer Pumps and FOG Feed Pumps are shut off when tank level falls below

the minimum low-liquid level.

The vents from the tanks are routed to a passive odor control system. This system is two

passive activated carbon barrels adjacent to the temporary tanks.

Each tank has four mixers installed, which are operated by tank-mounted control panels.

Mixers are ON-OFF, controlled by a hand switch on the tank-mounted panels. Individual

control of each mixer is not available.

Feed to the digesters is provided by variable speed progressing cavity pumps with a range of

approximately 2 to 50 gpm. Existing FOG Feed pumps 715P6402 and 715P6404 are

temporarily relocated outside of the Brown Grease Receiving Facility to the south. Flow rate

setpoint is entered by operator based on experience. An operator-initiated flushing system

using heated plant non-potable water is available to periodically clean the digester feed pipes.

Two FOG waste pipes from the feed pumps to the digesters provide redundancy should one

of the pipes become clogged.

FOG Feed flow meters 750FIT6402 and 715FIT6404 are located in the lower level of DC-2.

There are two SCADA AUTO modes: SCADA AUTO – FLOW and SCADA AUTO –

BUBBLE.

SCADA AUTO – FLOW:

Each digester is fed FOG continuously and the flowrate is a simple operator set point. Care

should be taken when selecting a set point to prevent overloading of FOG into the digesters

and to ration FOG so it does not run out before the next delivery. Flowrates are usually

between 5-10 gpm.

SCADA AUTO – BUBBLE:

The digester FOG flowrate is adjusted based on a direct feedback loop. The system will look

at the digester gas bubble storage and adjust the flowrate up or down as necessary to maintain

85%-90% full. This will help maximize gas production as the engines will be running at full

capacity and flaring will be unnecessary. When a FOG tank level reaches a designated low

level (operator adjustable), the FOG feed rate will be dropped to a designated low flowrate to

ensure that there is enough FOG until the next delivery. Initially this is set to be XX gallons

to be consumed over XX days. The digesters remain more stable when FOG is delivered

consistently.

Materials of construction and instrumentation are capable of operating at elevated

temperatures up to 150 degrees F.


FOG volume below EL161.50 of FOG storage tanks are not accessible by the feed pumps due

suction line elevation.


Equipment

Unit Equipment:



Cavity 2 – 50 gpm


Cavity 2 – 50 gpm

FOG Feed Pump 1 Suction Flush Valve 715SV6405 Solenoid

FOG Feed Pump 2 Suction Flush Valve 715SV6406 Solenoid

Digester Gas Storage Tank 740T6901 Dual-

Membrane

FOG Waste Receiving Tank 3

(Temporary) 715T6403 Baker Tank


(Temporary) 715T6404 Baker Tank

Instrumentation
















Gas Storage Tank Gas Level

Transmitter 740LIT6901 Laser 0-100%


Control Strategies





a. Shutdown interlocks for each Feed Pump:

i. Pump Stator Temperature HIGH.

ii. Pump Discharge Pressure HIGH.

b. For Feed Pumps:



iii. REMOTE control from SCADA



1. SCADA Manual: For each Pump:



c. Press the HMI START button to start the equipment.

d. Press the HMI STOP button to stop the equipment.

2. SCADA Auto:

Flow mode:

a. In SCADA AUTO – FLOW mode, the mixer runs whenever the associated tank

level is above the mixer minimum submergence, as specified by the mixer

manufacturer.

b. The FOG Feed Pumps operate continuously. FOG Feed pump speed is

controlled to maintain an operator-entered flow setpoint.

c. Stop pump if associated tank is below low-low level shutoff

a. Tank #1 EL161.50

b. Tank #2 EL161.50

d. Prior to starting a FOG Feed pump, open the suction side flush solenoid for a

preset time (0 to 30 seconds). This will flush the tank sump area.

Bubble Mode:

a. In SCADA AUTO – BUBBLE mode, the mixer runs whenever the associated

tank level is above the mixer minimum submergence, as specified by the mixer

manufacturer.

b. The FOG Feed Pumps operate continuously. A direct feedback loop will

increase or decrease the FOG pump speed to keep the gas bubble 85-90%.

c. There is a tank level setpoint for minimum flow. When the FOG tanks reach this

point, they will revert to the low flow setpoint in order to conserve FOG.

a. Typical low flow setpoint will be 5 gpm

b. Typical low tank level setpoint for low flow will be EL161.50

d. Stop pump if associated tank is below low-low level shutoff

a. Tank #1 EL161.50

b. Tank #2 EL161.50


SCADA Display


1. For each Pump:

a. ON status.

b. REMOTE mode.

c. Flush valve OPEN.

d. Speed.

e. Flow rate and total.


1. For each Pump:



2. BUBBLE or FLOW mode selection

3. For each pump:

a. FOG Feed flow setpoint. (FLOW mode)

b. FOG max/min flowrate (BUBBLE mode)

c. Controlling level transmitter selection (reflects manual valve setup for pump

suction)

4. For each Tank:

a. Tank level setpoint for minimum flow (BUBBLE mode)

5. Pre-flush solenoid time setting.

6. Duty pump selection 1/ALT/SPLIT/2.


1. For Tank 1:

a. Level.

2. For each Pump:

a. Flow rate.

b. Pump Speed.

3. Quick trend:

a. Gas Bubble Level and FOG Flow and GT3 underflow pump speed and sum of

gas use (engine ½ and flare ½ and boilers)


A. Alarms:

1. For each Pump:

a. FAIL alarm.

b. FAIL to Start and FAIL to Stop alarms.

c. LOW flow when the flow is less than 2 gpm for 60 seconds while the pump is

running.

d. HIGH discharge pressure.

e. HIGH stator temperature.

f. FOG Tank Low Level

B. Hard-Wired Interlocks:

1. Shutdown interlocks for each Feed Pump:

a. Pump Stator Temperature HIGH.

b. Pump Discharge Pressure HIGH.



1. Interlock each Pump with LOW-LOW level in associated Tank (EL161.50); stop

Pump below LOW-LOW level.

2. Interlock each Pump with READY signal from DC2.


A. Equipment Run Time Counters: Run Time for each Pump.



END OF DOCUMENT

Durham AWWTF – FOG Tank Retrofit Project Control Loop Description 3



Control Loop Description Digester FOG Feed


Digester FOG Feed Valves are motorized valves located at the digester feed manifold in DC2.

Valves open to direct FOG feed flow to selected digester. Automatic operation is a time-cycle

alternation between available digesters. When FOG Feed is selected for SPLIT mode, then both

Digester FOG Feed Valves are opened and a manual isolation valve is closed to isolate the feed

to the digesters. In SPLIT mode, FOG is fed to Digester 1, and Pacific Foods waste is fed to

Digester 2.

The valve operation as described is not synchronized with sludge feed. At a later date it may be

desirable to synchronize FOG feed with sludge feed (either feed at the same time or at opposite

times).

Last Update: November 25, 2014 Approved By:

Equipment

Unit Equipment:


DC2 Digester 1 FOG Feed Valve 750FV3803

DC2 Digester 2 FOG Feed Valve 750FV3804

DC2 Digester 1 FOG Feed Valve

Local Control Station 750FV3803-LCS

DC2 Digester 2 FOG Feed Valve

Local Control Station 750FV3804-LCS

Instrumentation





Control Strategies



2. Motor Control Center: None.



a. All local control is provided at each valve actuator.

b. Operators select the operating mode via LOCAL-OFF/RESET-REMOTE

(LORR) selector at the valve actuator. Operation in each mode is described

below:

i. LOCAL MODE:

1. Place the LORR selector in LOCAL position.

2. The valve opens when the OPEN button is pressed.

3. The valve closes when the CLOSE button is pressed.

ii. REMOTE MODE:

1. Place the LORR selector in REMOTE position.

2. The valve opens when a remote OPEN command is received

from the SCADA system.

3. The valve closes when a remote CLOSE command is received

from the SCADA system.



1. SCADA Manual:

a. Place the Valve LOCAL-REMOTE selector in REMOTE.


c. Press the HMI OPEN button to open the Valve.

d. Press the HMI CLOSE button to close the Valve.

2. SCADA Auto:

a. In SCADA AUTO mode, the valve automatically cycles open and closed

whenever DC2 is selected to receive sludge.

b. If only one DC2 digester is selected online, then the associated feed valve is

commanded OPEN and left open.

c. Valve operation when FOG Feed mode is NOT selected as SPLIT: When more

than one digester is selected online (two now, up to four future), then valves are

opened and closed in a timed sequence. Operator enters time interval for

digester FOG feed. Starting with DC2 Digester 1, the associated valve is

opened for this time period. When the time has elapsed, the valve for DC2

Digester 2 is commanded OPEN. When Digester 2 valve is fully open, then

Digester 1 valve is commanded CLOSE. When Digester 2 valve has been open

for time period, the cycle repeats with Digester 1.

d. Valve operation when FOG Feed mode IS selected as SPLIT: Command both

valves OPEN and keep them open.




e. Send a READY for FOG signal to the FOG Feed Pumps at the Brown Grease

Building when:

i. NOT selected for SPLIT mode: Either valve is fully open.

ii. Selected for SPLIT mode: BOTH valves are fully open.

SCADA Display


1. For each Digester Feed Valve:

a. Fully OPEN status.

b. Fully CLOSED status.

c. Valve in REMOTE mode.


1. SCADA MANUAL / AUTO selection for each valve.

2. SCADA MANUAL OPEN and CLOSE buttons for each valve.

3. DC2 FOG Feed ON / OFF selection.

4. DC2 Digester 1 ONLINE selection.

5. DC2 Digester 2 ONLINE selection.

6. Digester Feed Sequence Time Interval, adjustable from 5 to 60 minutes.

C. SCADA Historical Trending: None.


A. Alarms:

1. For each Valve:

a. FAIL to OPEN alarm.

b. FAIL to CLOSE alarm.

B. Hard-Wired Interlocks: None.

C. Software Interlocks: See control loops for FOG Feed Pumps and FOG Waste

Receiving.


A. Equipment Run Time Counters: None.



END OF DOCUMENT


Control Loop Description FOG Waste Receiving and Recirculation


Screen Receiving:

A single, 4-inch quick connect hose fitting is provided on the south side of the building for

unloading FOG waste into the screen from the hauling trucks. Each driver is issued an

identification code that is used for each delivery. Entering the correct code at the unloading

system control panel system initiates a request for unloading cycle to begin. The unloading

control system records the delivery company, the particular driver, and the date and time. Once

the code/card has been accepted and the truck discharge hose connected, the driver pushes a

button to begin an automated unloading cycle. The plant SCADA PLC checks the beginning

fluid level in the FOG waste receiving tanks to determine if there is adequate volume and, in

what tank, for an assumed 5,000 gallon delivery. Once sufficient freeboard volume has been

determined, the SCADA PLC sends a signal for the FOG Waste Screen Transfer Valve to open

to the corresponding tank then sends a ready signal to the screen main control panel PLC to

begin the screen unloading process. The vendor control panel PLC initiates the control

sequence for operation of the vendor equipment. The auger and drum are energized, the

receiving motorized valve is opened and FOG begins to flow to the FOG Waste Screen. The

FOG Waste Screen Offload Pump is controlled by the liquid level in the Screen basin as

detected by the effluent pressure transducer. When the level rises to the start level, the offload

pump begins to run. Offload Pump speed varies linearly between the low speed and high speed

based on low speed level and high speed level settings in the VFD and the effluent pressure

level readings. The offload pump will continue to run after the level falls below the start level

for the time set in the offload pump time delay. The driver will push a button on the unloading

system control panel to conclude the unloading cycle. As a fail-safe, if the driver fails to push

the button to complete the unloading cycle within a set period of time, the system will override

to end the unloading cycle.

Backup Receiving through Rock Trap:

A single, 4-inch quick connect hose fitting is provided on the outside of the building for

unloading FOG waste from the hauling trucks. Each driver is issued an identification code that

is used for each delivery. Entering the correct code at the unloading system control panel

system enables an unloading cycle to begin. The unloading control system records the delivery

company, the particular driver, the date and time, and the amount of FOG waste unloaded.

Once the code/card has been accepted and the truck discharge hose connected, the driver pushes

a button to begin an automated unloading cycle. The plant SCADA PLC checks the beginning

fluid level in the FOG waste receiving tank to determine if there is adequate volume in the tank

for an assumed 5,000 gallon delivery. Once sufficient freeboard volume has been determined,

the associated equipment operates to receive the FOG waste: 1) the receiving motorized valve

is opened, 2) the pump transfer inlet motorized valve is opened, 3) the tank recirculation

motorized valve is closed, and 4) the FOG Waste Grinder and Transfer Pump are energized.

While unloading, the plant PLC monitors flow pulses from flowmeter for the operating pump

and passes these pulses to the receiving station for volume totalization. The driver will push a

button on the control panel to conclude the unloading cycle. The receiving station then records

the volume delivered. As a fail-safe, if the driver fails to push the button to complete the

unloading cycle within a set period of time, the system will override to end the unloading cycle.


Inside the building, a sediment/rock trap removes the large and heavy objects being unloaded

before being pumped into the storage tanks. There are two trains of FOG transfer lines after the

single sediment/rock trap. In each train, an in-line grinder operates whenever the associated

transfer pump is on to ensure that the soft materials and plastics are reduced to small pieces and

produce a more homogenized fluid. The FOG Waste Transfer Pump is a rotary lobe pump that

will draw FOG from the trucks to fill the storage tank. The discharge from each pump passes

through a heat exchanger before entering the receiving tank. A grinder, pump system, and heat

exchanger make up each of two receiving trains.

Recirculation:

The FOG Waste Transfer Pumps are also used for recirculation of the stored FOG waste

through the heat exchanger to raise the FOG temperature to a minimum desired temperature

before feeding the material to the digesters. The heat exchangers will bring the FOG waste up

to a temperature between 80 and 100 degrees F over a 12-hour period. Each heat exchanger has

a hot water pump and control valve to apply heat whenever the transfer pump is on. When the

transfer pump is off, the hot water pump is stopped and the hot water valve is closed to prevent

overheating of the FOG.

Recirculated FOG waste exits the tanks through the 6” FOG/RCY nozzle, passes through the

FOG Waste Transfer Pump and FOG Waste Heat Exchanger, and is returned to the applicable

storage tank through two nozzles positioned above the tank cone. The nozzles reduce from 6”

NPD to 2” NPD and direct the recirculated FOG upwards at 45 degrees and in a counterclockwise

direction.

The FOG Waste Transfer Pumps can also be used to transfer FOG waste between tanks. This is

done by operating the associated pump, grinder and valves in SCADA Manual mode and with

the crossover valve, FV-6409, closed.


Equipment

Unit Equipment:


Rock Trap Custom

FOG Waste Grinder 1 715GDR6401 In-line 300 gpm

FOG Waste Transfer Pump 1 715P6401 Rotary Lobe 300 gpm

FOG Waste Heat Exchanger 1 715HX6401

FOG Hot Water Pump 1 715P6603

FOG Waste Grinder 2 715GDR6402

FOG Waste Transfer Pump 2 715P6403 In-line 300 gpm

FOG Waste Heat Exchanger 2 715HX6402 Rotary Lobe 300 gpm


FOG Waste Receiving Valve 715FV6407


FOG Waste Transfer Inlet Valve 1 715FV6401

FOG Waste Recirculation Valve 1 715FV6402

FOG Waste Tank Inlet Valve 1 715FV6403




FOG Waste Switchover Valve 715FV6408

FOG Hot Water Return Valve 1 715FCV6601


FOG Waste Screen 715SCR6401

FOG Waste Screen Offload Pump 715P6405 Rotary Lobe 300 gpm

FOG Waste Crossover Valve 715FV6409

FOG Waste Screen Transfer Valve 1 715FV6410

FOG Waste Screen Transfer Valve 2 715FV6411

FOG Waste Screen Receiving Valve 715FV6412

FOG Waste Receiving Station 715VCP6403

Instrumentation


FOG Waste Transfer Pump 1

Discharge Pressure Switch 715PSH6401 50 psig


Discharge Pressure Gauge 715PI6401 0 – 60 psig

FOG Waste HX 1 Hot Water

Temperature Transmitter 715TIT6603 0 – 240 deg F


Recirculation Temperature

Transmitter

715TIT6401 0 – 150 deg F


Discharge Flow Meter 715FIT6401 0 – 600 gpm










Transmitter

715TIT6402 0 – 150 deg F



FOG Waste Screen Offload

Pump Discharge Pressure Switch 715PSH6405 50 psig


Pump Discharge Pressure Gauge 715PI64XX 0 – 60 psig


Pump Stator Temperature Switch 715TSH6405


Pump Motor Temperature

Element

715RTD6405

FOG Waste Screen Effluent

Pressure Transducer 715PT6401 0 – 60 psig

Control Strategies

A. Local Control Operation and Alarm Reset: See equipment specifications for control

loop descriptions.

1. Manufacturer-Supplied Control Panels:

a. Place the Grinder LOCAL-REMOTE selector in LOCAL.

b. Press the START FORWARD button to run Grinder FORWARD.

c. Press the START REVERSE button to run Grinder in REVERSE.

d. Press the STOP button to stop the Grinder.


e. Place the Screen LOCAL-REMOTE selector in LOCAL.

f. Press the START button to run Screen.

g. Press the STOP button to stop the Screen.





a. For Transfer Pumps: HIGH discharge pressure shutdown.

b. For Transfer Pumps and Hot Water Pumps:



iii. REMOTE control from SCADA.

c. For Screen Offload Pump: HIGH temperature and HIGH discharge pressure

shutdown.




d. For Valves:


ii. OPEN and CLOSE pushbuttons for LOCAL control.




1. SCADA Manual:



c. Press the HMI START button to start the equipment. Press the HMI OPEN button

to open a valve.

d. Press the HMI STOP button to stop the equipment. Press the HMI CLOSE button

to close a valve.

2. SCADA Auto:

a. Provide selection of receiving train, as 1/ALT/SPLIT/2/3. When 1 or 2 is selected,

then that pump and grinder is always used for receiving FOG waste. When ALT is

selected, then the receiving pump and grinder trains are alternated on a daily

basis, at 8:00 am (adjustable). When SPLIT is selected, the receiving pump and

grinder train is selected based on the type of waste being unloaded. When 3 is

selected, the FOG screen and FOG waste screen offload pump are used for

receiving FOG waste. The waste type is identified from the unloading control

system based on the driver code. Train 3 is the default receiving train for normal

FOG receiving operations.

b. The tanks must have 6,000 gallons of freeboard to enable receiving a load. This

corresponds to a tank level of no greater than EL185.25; both tanks must be below

this level to enable receiving a load.

c. Each tank has an inlet valve. A crossover valve ties the tanks together and allows

the contents of one tank to be transferred to the other. When selected for SCADA

AUTO, the tank inlet valves are commanded open, and the crossover valve is

commanded closed. If these valves are in SCADA MANUAL mode, waste

receiving and recirculation can operate automatically as long as the tank valves

meet one of these conditions:

i. Tank inlet valve associated with the operating train is open; OR


ii. SPLIT mode is NOT selected AND the crossover valve is open AND the

tank inlet valve associated with the non-selected train is open.

d. Receiving Mode: If a RUN REQUEST is received from the Waste Receiving

Station, and the tanks have sufficient freeboard, operate selected train in this

sequence:

Trains 1 and 2

i. Stop pumps and grinder if they were running.

ii. Close recirculation valve.

iii. Open receiving valve. Open transfer pump inlet valve for selected train.

iv. Start pump and grinder to accept FOG waste.

v. Start hot water pump and modulate hot water valve to add heat to FOG

waste.

vi. Take flow pulses from the flow meter on the selected train and re-send the

flow pulse to the Waste Receiving Station for volume calculation.

vii. Continue operating until “RUN REQUEST” is removed or the level in

either tank rises above EL188.5.

Train 3 (Screen Receiving)

i. Open tank recirculation valve and tank inlet valve associated with tank

with sufficient freeboard to intake haul truck volume (Train 1 or Train 2).

ii. Start transfer pump and grinder associated with train from step above.

iii. Open screen receiving valve.

iv. Start screen auger and screen drum to accept FOG waste.

v. Screen offload pump will start when screen level reaches the start level

programmed in the FOG screen main control panel PLC.

vi. Continue operating until “RUN REQUEST” is removed or the level in

either tank rises above EL 188.50.

e. Recirculation Mode: When “RUN REQUEST” is removed, go into recirculation

mode:

i. Stop pumps and grinder if they were running.

ii. Open recirculation valve for selected train.

iii. Close receiving valve. Close transfer pump inlet valve for selected train.

iv. Start pump and grinder to circulate FOG waste.


waste.

vi. Do not re-send flow pulses.

vii. Start a recirculation cycle. Duration of run time to be selectable based on a

minimum run time (adjustable 0 to 60 minutes) or on tank level. If based on

tank level, run time is calculated for one complete cycle through liquid

volume in tank.

viii. Continue recirculation until FOG waste temperature reaches setpoint

(adjustable from 80 to 100 degrees F).

ix. Stop pumps and grinder and close hot water valve.

x. If pumps are off for more than a set OFF time (adjustable 0 to 120 minutes)

then perform another recirculation cycle.

f. For the train that is not selected for receiving, if all equipment is in SCADA

AUTO and has not failed, then run that train in recirculation mode as per above.

g. Signal “READY” from Plant PLC as long as the selected train equipment is in

SCADA AUTO and does not have a failure. If selected train is not in SCADA


AUTO, or a pump or valve failure occurs, open the READY contact. Also open

the READY contact if there is not sufficient freeboard in the tank(s) prior to

receiving a new load.

h. In SCADA AUTO mode, the hot water pump, hot water valve, and grinder run

whenever the associated pump is running.

i. If the grinder has failed or is not in SCADA AUTO mode, disable the automatic

operation of the associated pump.

SCADA Display


1. For each Pump and Grinder:

a. ON FORWARD status.

b. ON REVERSE status.

c. REMOTE mode.

d. FAIL alarm.

2. For each Valve:



c. REMOTE mode.

3. For Screen:

a. ON status.

b. REMOTE mode.

c. FAIL alarm.

4. FOG Waste flow rate and total for each train.

5. FOG Waste Receiving flow total for each train, accumulate total only when train is in

Receiving mode.

6. FOG Waste temperature for each train.

7. Hot water temperature for each train.





2. For Screen:



3. For each Valve:


b. MANUAL OPEN/CLOSE control.

4. Selection of Duty Train (associated pumps, valves, and tank): 1/ALT/SPLIT/2/3.

5. FOG Waste Temperature setpoint.

6. FOG Recirculation Cycle: Selectable duration based on minimum run time (0 - 90

minutes) or liquid volume.

7. FOG Recirculation OFF time: Selectable duration based upon minimum settling time

(0-30 minutes).


1. FOG Waste flow rate for each train.


2. FOG Waste temperature for each train.

3. Hot water temperature for each train.


A. Alarms:

1. For each Screen, Pump, Grinder, and Valve:

a. FAIL alarm.

2. For each Transfer and Offload Pump: HIGH temperature and HIGH discharge pressure.

3. For each Train: FOG Waste Temperature LOW when in recirculation mode for 5

minutes.



1. For each Pump, Grinder, and Valve: Interlock each Grinder and Hot Water Pump and

Valve with associated Transfer Pump. If the pump is off, then stop all associated

elements.

2. Stop pump if associated tank is below low-low level shutoff.


A. Equipment Run Time Counters: Run Time for Screen, and each Grinder and Pump.



END OF DOCUMENT


Control Loop Description Temporary FOG Waste Receiving and

Recirculation


A single, 4-inch quick connect hose fitting is provided on the outside of the building for

unloading FOG waste from the hauling trucks. Each driver is issued an identification code that

is used for each delivery. Entering the correct code at the unloading system control panel

system enables an unloading cycle to begin. The unloading control system records the delivery

company, the particular driver, the date and time, and the amount of FOG waste unloaded.

Once the code/card has been accepted and the truck discharge hose connected, the driver pushes

a button to begin an automated unloading cycle. The plant SCADA PLC checks the beginning

fluid level in the FOG waste receiving tank to determine if there is adequate volume in the tank

for an assumed XXXX gallon delivery. Once sufficient freeboard volume has been determined,

the associated equipment operates to receive the FOG waste: 1) the receiving motorized valve

is opened, 2) the pump transfer inlet motorized valve is opened, 3) the tank recirculation

motorized valve is closed, and 4) the FOG Waste Grinder and Transfer Pump are energized.

While unloading, the plant PLC monitors flow pulses from flowmeter for the operating pump

and passes these pulses to the receiving station for volume totalization. The driver will push a

button on the control panel to conclude the unloading cycle. The receiving station then records

the volume delivered. As a fail-safe, if the driver fails to push the button to complete the

unloading cycle within a set period of time, the system will override to end the unloading cycle.

Inside the building, a sediment/rock trap removes the large and heavy objects being unloaded

before being pumped into the storage tanks. There is one FOG transfer line after the single

sediment/rock trap. One in-line grinder operates whenever the transfer pump is on to ensure

that the soft materials and plastics are reduced to small pieces and produce a more homogenized

fluid. The FOG Waste Transfer Pump is a rotary lobe pump that will draw FOG from the trucks

to fill the temporary storage tanks. The discharge from the pump passes through a heat

exchanger before entering the temporary receiving tanks. A grinder, pump system, and heat

exchanger makes up the receiving train.

The two temporary FOG tanks are hydraulically coupled by a connecting pipe. There is no

inter-tank isolation valve.

The FOG Waste Transfer Pump is also used for recirculation of the stored FOG waste through

the heat exchanger to raise the FOG temperature to a minimum desired temperature before

feeding the material to the digesters. The heat exchangers will bring the FOG waste up to a

temperature between 80 and 100 degrees F over a 12-hour period. The heat exchanger has a hot

water pump and control valve to apply heat whenever the transfer pump is on. When the

transfer pump is off, the hot water pump is stopped and the hot water valve is closed to prevent

overheating of the FOG.



Equipment

Unit Equipment:


Rock Trap Custom

FOG Waste Grinder 2 715GDR6402

FOG Waste Transfer Pump 2 715P6403 In-line 300 gpm

FOG Waste Heat Exchanger 2 715HX6402 Rotary Lobe 300 gpm


FOG Waste Receiving Valve 715FV6407





FOG Waste Receiving Station 715VCP6403

Instrumentation










Transmitter

715TIT6402 0 – 150 deg F



Control Strategies

A. Local Control Operation and Alarm Reset: See equipment specifications for control

loop descriptions.


a. Place the Grinder LOCAL-REMOTE selector in LOCAL.

b. Press the START FORWARD button to run Grinder FORWARD.

c. Press the START REVERSE button to run Grinder in REVERSE.

d. Press the STOP button to stop the Grinder.





a. For Transfer Pump: HIGH discharge pressure shutdown.

b. For Transfer Pump and Hot Water Pump:




c. For Valves:


ii. OPEN and CLOSE pushbuttons for LOCAL control.




1. SCADA Manual:



c. Press the HMI START button to start the equipment. Press the HMI OPEN button

to open a valve.

d. Press the HMI STOP button to stop the equipment. Press the HMI CLOSE button

to close a valve.

2. SCADA Auto:

a. Only receiving train 2 is available during temporary operations. For train 2, the

pump and grinder is always used for receiving FOG waste. The waste type is

identified from the unloading control system based on the driver code.

b. The tanks must have 6000 gallons of freeboard to enable receiving a load. This

corresponds to a tank level of no greater than EL168.00; both tanks must be below

this level to enable receiving a load.

c. When selected for SCADA AUTO, the tank inlet valve (715FV6406) is

commanded open.

d. Receiving Mode: If a RUN REQUEST is received from the Waste Receiving

Station, and the tanks have sufficient freeboard, operate train 2 in this sequence:

i. Stop pump and grinder if they were running.

ii. Close recirculation valve.

iii. Open receiving valve. Open transfer pump inlet valve.

iv. Start pump and grinder to accept FOG waste.


waste.

vi. Take flow pulses from the flow meter and re-send the flow pulse to the

Waste Receiving Station for volume calculation.

vii. Continue operating until “RUN REQUEST” is removed or the level in

either tank rises above EL 168.00.

e. Recirculation Mode: When “RUN REQUEST” is removed, go into recirculation

mode:

i. Stop pump and grinder if they were running.


ii. Open recirculation valve.

iii. Close receiving valve. Close transfer pump inlet valve.

iv. Start pump and grinder to circulate FOG waste.


waste.

vi. Do not re-send flow pulses.

vii. Start a recirculation cycle. Duration of run time to be selectable based on a

minimum run time (adjustable 0 to 60 minutes) or on tank level. If based on

tank level, run time is calculated for one complete cycle through liquid

volume in tank.

viii. Continue recirculation until FOG waste temperature reaches setpoint

(adjustable from 80 to 100 degrees F).

ix. Stop pump and grinder and close hot water valve.

x. If pump is off for more than a set OFF time (adjustable 0 to 120 minutes)

then perform another recirculation cycle.

f. Signal “READY” from Plant PLC as long as the train equipment is in SCADA

AUTO and does not have a failure. If train is not in SCADA AUTO, or a pump or

valve failure occurs, open the READY contact. Also open the READY contact if

there is not sufficient freeboard in the tank(s) prior to receiving a new load.

g. In SCADA AUTO mode, the hot water pump, hot water valve, and grinder run

whenever the pump is running.

h. If the grinder has failed or is not in SCADA AUTO mode, disable the automatic

operation of the pump.

SCADA Display



a. ON FORWARD status.

b. ON REVERSE status.

c. REMOTE mode.

d. FAIL alarm.

2. For each Valve:



c. REMOTE mode.

3. FOG Waste flow rate and total.

4. FOG Waste Receiving flow total, accumulate total only when train is in Receiving

mode.

5. FOG Waste temperature.

6. Hot water temperature.





2. For each Valve:


b. MANUAL OPEN/CLOSE control.

3. Selection of Duty Train (associated pumps, valves, and tank): 2.


4. FOG Waste Temperature setpoint.

5. FOG Recirculation Cycle: Selectable duration based on minimum run time (0 - 60

minutes) or liquid volume.

6. FOG Recirculation OFF time.


1. FOG Waste flow rate.

2. FOG Waste temperature.

3. Hot water temperature.


A. Alarms:

1. For each Pump, Grinder, and Valve:

a. FAIL alarm.

2. For Transfer Pump: HIGH discharge pressure.

3. FOG Waste Temperature LOW when in recirculation mode for 5 minutes.



1. For each Pump, Grinder, and Valve: Interlock each Grinder and Hot Water Pump and

Valve with Transfer Pump. If the pump is off, then stop all associated elements.

2. Stop pump if associated tank is below low-low level shutoff.


A. Equipment Run Time Counters: Run Time for each Grinder and Pump.



END OF DOCUMENT




Control Loop Description Heating Loads FOG Waste Receiving


FOG Hot Water Pumps provide hot water circulation to heat FOG receiving and recirculation

at the heat exchanger downstream of the FOG Transfer Pumps. A modulating valve adjusts

hot water flow into the pump loop to maintain temperature at the pump discharge.

Hot water is also used for Brown Grease Building heating loads. A makeup air unit and unit

heater provide heat to the building. The building is ventilated continuously, and ventilation is

monitored for fan failure with alarm and GO/NO-GO lights.

Last Update: April 29, 2014 Approved By:

Equipment

Unit Equipment:






Brown Grease Building Unit Heater 715UH8001

Brown Grease Building Makeup Air

Unit 715MAU8001

BG Building Ventilation Fail Alarm

Panel 715LCP8001

Instrumentation


FOG Hot Water Pump 1 HWS


FOG Hot Water Pump 2 HWS


FOG Hot Water Pump 1 HWR

Temperature Gauge 715TI6601 32 – 240 deg F

FOG Hot Water Pump 2 HWR

Temperature Gauge 715TI6602 32 – 240 deg F

Control Strategies






2. Motor Control Center/VFD: Motor overload RESET.


4. Local Control Station: LOCAL/OFF-RESET/REMOTE selection.



1. SCADA Manual:

a. Place the Pump LOCAL-REMOTE selector in REMOTE.


c. Press the HMI START button to start the Pump.

d. Press the HMI STOP button to stop the Pump.

2. SCADA Auto:

a. Pumps run whenever the associated FOG Transfer Pump is running.

b. When the pump is on, modulate the FCV to maintain pumped hot water

temperature setpoint. If the temperature rises above setpoint, the valve

modulates closed. If the pump is off, the FCV fully closes.

SCADA Display


1. For each Pump:

a. ON status.

b. REMOTE mode.

c. Valve Position.

d. FOG HWS Temperature.

2. For Exhaust Fan: ON status.


1. For each Pump:



2. FOG HWS Temperature setpoint.


1. FOG HWS Temperature.


A. Alarms:

1. For each Pump:

a. FAIL alarm.

b. LOW Temperature

c. HIGH Temperature

2. For Exhaust Fan: FAIL alarm.

3. Brown Grease Building Ventilation FAIL.

B. Hard-Wired Interlocks: GO/NO-GO lights for ventilation failure.

C. Software Interlocks: None.


A. Equipment Run Time Counters: Run Time for each Pump and Fan.





C. Equipment Automatic Failover Sequence: If FOG Transfer pump fails, stop the

associated FOG Hot Water pump.

END OF DOCUMENT

Durham AWWTF – FOG Tank Retrofit Project Rotameters (Variable Area Flow Meters)



17316 - 1

SECTION 17316

ROTAMETERS (VARIABLE AREA FLOW METERS)

GENERAL

1.01 SUMMARY

A. Section includes requirements for:

1. Rotameters (variable area flow meters).

B. Related Sections:

1. The Contract Documents are a single integrated document, and as such all Divisions

and Sections apply. It is the responsibility of the CONTRACTOR and its Sub-

Contractors to review all sections to ensure a complete and coordinated project.

C. Provide all instruments identified in the Contract Documents.

1.02 REFERENCES

A. Refer to Section 17050, Basic Measurement and Control Instrumentation Materials and

Methods.

B. Refer to Section 17901, Instrument List for calibration and other requirements.

1.03 DEFINITIONS


Methods.

1.04 SUBMITTALS

A. Furnish submittals in accordance with Section 01330, Submittal Procedures and Section

17050, Basic Measurement and Control Instrumentation Materials and Methods.



Methods.

B. Examine the complete set of Contact Documents and verify that the instruments are

compatible with the installed conditions including:

1. Process conditions: Fluids, pressures, temperatures, flows, materials, etc.

2. Physical conditions:

a. Installation and mounting requirements.

b. Location within the process.

c. Accessories: Verify that all required accessories are provided and are compatible

with the process conditions and physical installation.

C. Notify the ENGINEER if any installation condition does not meet the instrument

manufacturer’s recommendations or specifications.




17316 - 2



Methods.



Methods.

1.08 WARRANTY


Methods.

1.09 MAINTENANCE


Methods.

PRODUCTS

2.01 MANUFACTURERS


1. ABB.

2. Brooks.

3. King Instrument Company.


A. Rotameters:

1. General:

a. Variable area type flow meters with local flow indication.

b. Glass Tube type.

2. Performance requirements:

a. Flow Range:

1) As specified by pump manufacturer.

b. Accuracy:

1) Glass Tube: ±2.0 percent of range.

2) Repeatability: 0.50 percent of range.

3. Element:

a. Flow tube:

1) Glass Tube: Borosilicate glass, or as required to be compatible with the

process conditions.

b. Turndown: 10 to 1.

c. Process Temperature:

1) Glass Tube: 32 to 150 degrees Fahrenheit.




17316 - 3

d. Maximum Process Pressure:

1) Glass Tube: 100 psig.

2) Size tube for the largest of the following:

a) 2.0 times the normal flow rate.

b) 1.2 times the maximum flow rate.

c) 4.0 times the minimum flow rate.

e. Float:

1) Design to provide the widest possible immunity band change in viscosity.

2) Metal Tube Rotameters: float with encapsulated magnet.

4. Components:

a. Seals: O-rings or packing glands fully compatible with process fluid.

b. Integral needle valve for flow control.

c. [Integral Alarm Limit Switches:

1) Dual alarm.

2) Adjustable by repositioning alarm switches.]

5. Scale:

a. Metal Tube: Dial indicator with rotatable magnet coupled to magnet

encapsulated in rotameter float.

6. Other:

a. Process Connection:

1) As indicated on the Mechanical Drawings.

b. Mounting:

1) As indicated on the Drawings.

2) Provide all necessary hardware for rotameter mounting.



Methods.

EXECUTION

3.01 INSTALLATION


Methods.

B. Coordinate the installation with all trades to ensure that the mechanical system has all

necessary appurtenances including weld- o-lets, valves, etc. for proper installation of

instruments.



Methods.




17316 - 4

3.03 ADJUSTING

A. Verify factory calibration of all instruments in accordance with the manufacturer’s

instructions:

1. Return factory calibrated devices to the factory if they do not meet the field

verification requirements for calibration.

3.04 CLEANING


Methods.



Methods.

B. Demonstrate performance of all instruments to the ENGINEER before commissioning.

3.06 PROTECTION


Methods.

3.07 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide

all instruments identified in the Contract Documents:

1. Instruments may be shown on the Drawings, in the Specifications or both.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Pressure/Vacuum Measurement: Diaphragm and Annular Seals



17401 - 1

SECTION 17401

PRESSURE/VACUUM MEASUREMENT: DIAPHRAGM AND ANNULAR SEALS

GENERAL

1.01 SUMMARY


1. Diaphragm seals.

2. Annular seals.












b. Section 17050, Basic Measurement and Control Instrumentation Materials and

Methods.

C. Provide all seals identified in the Contract Documents.

1.02 REFERENCES

A. As specified in Section 17050, Basic Measurement and Control Instrumentation

Materials and Methods.

B. Refer to Section 17901, Instrument List for other requirements.

1.03 DEFINITIONS



1.04 SUBMITTALS

A. Furnish submittals as specified in Section 01330, Submittal Procedures and Section


B. Additional requirements:

1. Product data:

a. Manufacturer’s installation instructions.

b. Seal type.

c. Body materials.




17401 - 2

d. Diaphragm material.

e. Fill fluid type.

f. Seal size.

g. Options.

h. Process connection.




B. Examine the complete set of Contract Documents and verify that the instruments

are compatible with the installed conditions including:







C. Notify the Engineer if any installation condition does not meet the instrument








1.08 WARRANTY



1.09 MAINTENANCE






17401 - 3

PRODUCTS

2.01 MANUFACTURERS

A. Diaphragm seals:

1. For chemical applications, liquids containing solids, and liquids with pulsating flow

having pressures greater than or equal to 15 pounds per square inch gauge:


1) Rosemount 1199.

B. Annular seals:


a. Ashcroft Iso-Ring.

b. Onyx Valve.

c. Red Valve.


A. Diaphragm seals:

1. General:

a. Diaphragm seal and pressure instrument shall be assembled by pressure

instrument manufacturer and shipped as an assembly.

2. Requirements:

a. Seal type:

1) Metallic diaphragm: Welded to upper housing.

b. Process connection: 4 inch flange.

c. Instrument connection: 1/2 inch NPT.

d. Material Construction: Type 316 Stainless Steel.

e. Provide 1/4-inch flushing connection in diaphragm lower housing or provide

flushing ring.

f. Flush port plug: Same material of construction as diaphragm lower housing.]

g. Provide fill/bleed connection.

h. Mounting: As indicated in the Contract Documents.

i. Provide Type 316 stainless steel armored capillary for all remote installations.

j. Nuts and bolts: Type 316 stainless steel.

k. Materials of construction:

1) Sewage, sludge, liquids containing solids, and liquids with pulsating flow

having pressures less than or equal to 15 pounds per square inch:

a) Diaphragm: Type 316 stainless steel.

b) Lower housing: Type 316 stainless steel.

c) Upper housing: Manufacturer’s standard.

d) Fill fluid: Silicon oil.




17401 - 4

2) Sewage, sludge, liquids containing solids, and liquids with pulsating flow

having pressures greater than 15 pounds per square inch:

a) Diaphragm: Type 316 stainless steel.

b) Lower housing: Type 316 stainless steel.

c) Upper housing: Manufacturer’s standard.

d) Fill fluid: Silicon oil.

3) Engineer’s approval.

B. Annular seals:

1. General:

a. Inside diameter of annular seal shall provide uninterrupted flow:

1) There shall be no dead ends or crevices.

2) Process flow shall be sufficient to make the annular seal self-cleaning.

b. The pressure sensing flexible cylinder shall measure pressure around the full

inside circumference of the pipeline.

2. Requirements:

a. Pressure rating: Equivalent to the ANSI flanges.

b. Materials of construction:

1) Inner flexible cylinder: Manufacturer’s standard.

2) Body:

a) Carbon Steel with epoxy coating.

3) Assembly flanges: To match adjacent piping.

4) Fill fluid: Silicon oil.

c. Nominal pipe size: As indicated on the Drawings.

d. Process connection: Wafer.

e. Instrument connection: 1/2 inch NPT.

2.03 ACCESSORIES

A. Provide field fill kits.







17401 - 5

EXECUTION

3.01 INSTALLATION





instruments.

C. Do not use Teflon thread seal tape on pressure instruments with silicon oil fill fluid.




B. Provide manufacturer’s services to perform start-up and calibration or verification.

3.03 ADJUSTING


instructions:



3.04 CLEANING






3.06 PROTECTION



3.07 SCHEDULES



1. Instruments may be indicated on the Drawings, in the Specifications or both.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Pressure/Vacuum Measurement – Instrument Valves



17402 - 1

SECTION 17402

PRESSURE/VACUUM MEASUREMENT - INSTRUMENT VALVES

GENERAL

1.01 SUMMARY

A. Section includes requirements for:

1. Valve manifolds and instrument valves.

B. Related Sections:

1. The Contract Documents are a single integrated document, and as such all Divisions

and Sections apply. It is the responsibility of the CONTRACTOR and its Sub-

Contractors to review all sections to ensure a complete and coordinated project.

C. Provide all valve manifolds and instrument valves identified in the Contract Documents.

1.02 REFERENCES


Methods.

1.03 DEFINITIONS


Methods.

1.04 SUBMITTALS

A. Furnish submittals in accordance with Section 01330, Submittal Procedures and Section


B. Additional Requirements:

1. Product Data:

a. Valve type.

b. Body material.

c. Size.

d. Options.

2. Shop Drawings:

a. Mounting details for all manifold valves.



Methods.

B. Examine the complete set of Contact Documents and verify that the instruments are






17402 - 2






C. Notify the ENGINEER if any installation condition does not meet the instrument




Methods.

B. Protect valve manifolds and protective coatings from damage during handling and

installation. Repair coating where damaged.



Methods.

1.08 WARRANTY


Methods.

1.09 MAINTENANCE


Methods.

PRODUCTS

2.01 MANUFACTURERS

A. Valve Manifold Manufacturers: One of the following or equal:

1. Anderson Greenwood.

2. Hex Valve.

3. Noshok.

4. Rosemount.

B. Block and Bleed Valve Manufacturers: One of the following or equal:


2. Hex Valve.

C. Gauge Valve Manufacturers: One of the following or equal:


2. Hex Valve.




17402 - 3


A. Valve Manifolds:

1. General:

a. Provide 2-Valve, 3-valve, blowdown type 5-valve, or metering type 5-valve

manifolds as indicated on the Drawings.

b. Valve manifolds shall have one piece bonnet with a metal to metal seal to the

valve body below the bonnet threads.

2. Requirements:

a. Bonnet lock pin to prevent accidental loosening.

b. Gas leak tested metal-to-metal hard seat design for hard seat valves.

c. Gas leak tested soft seat design with replaceable seat for soft seat valves.

d. Manifold valves shall have straight through portion for bi- directional flow and

easy roddable cleaning.

e. Manifold valves shall allow for direct or remote instrument mounting.

f. Shall be able to withstand pressures up to 6,000 psi for soft seat valves and

10,000 psi for hard seat valves at maximum 200 degrees Fahrenheit.

g. Materials of Construction:

1) Body Material: 316 Stainless Steel.

2) O-Ring: Teflon.

h. 2-Valve Manifolds:

1) 1 isolation valve and 1 drain/vent and calibration valve.

i. 3-Valve Manifolds:

1) 2 isolation valves and 1 equalizing valve for differential pressure applications.

2) Plugged vent connections used for vent/drain or calibration.

j. Blowdown 5-Valve Manifold:

1) 2 isolation valves, 1 equalizing valve, 2 blowdown valves for differential

pressure applications.

k. Metering 5-Valve Manifold:

1) 2 isolation valves, 2 equalizing valves, 1 vent/drain and calibration valve for

differential pressure applications.

B. Block and Bleed Valves:

1. General:

a. Valve shall provide process isolation and venting/draining capabilities.

b. Gas leak tested metal-to-metal hard seat design for hard seat valves.


2. Requirements:

a. Materials of Construction:


2) O-Ring: Teflon.




17402 - 4

C. Gauge Valves:

1. General:

a. Valve shall provide process isolation from pressure instrument.

b. Gas leak tested metal to metal hard seat design for hard seat valves.


2. Requirements:

a. Materials of Construction:


2) O-Ring: Teflon.

2.03 ACCESSORIES

A. Provide tube fitting, female NPT, or pipe butt weld connections if necessary.

B. Provide stainless steel concentric or eccentric pipe nipples when necessary.



Methods.

B. Factory calibrate each instrument at a facility that is traceable to the National Institute of

Testing Standards (NIST).

EXECUTION

3.01 INSTALLATION


Methods.



instruments.



Methods.

B. Provide manufacturer’s services to perform start-up and calibration or verification.

3.03 ADJUSTING


instructions:






17402 - 5

3.04 CLEANING


Methods.



Methods.


3.06 PROTECTION


Methods.

3.07 SCHEDULES



1. Instruments may be shown on the Drawings, in the Specifications or both.

END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Pressure/Vacuum Measurement: Switches



17403 - 1

SECTION 17403

PRESSURE/VACUUM MEASUREMENT: SWITCHES

GENERAL

1.01 SUMMARY


1. Pressure/vacuum switches.












b. Section 17050 - Common Work Results for Process Control and Instrumentation

Systems.

c. Section 17401 - Pressure/Vacuum Measurement: Diaphragm and Annular Seals.

d. Section 17402 - Pressure/Vacuum Measurement: Instrument Valves.

C. Provide all instruments specified in the Contract Documents.

1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS



1. Product data:

a. Accessories such as diaphragm seals, valve manifold, snubbers, and pulsation

dampeners.






17403 - 2

B. Examine the complete set of Contract Documents and verify that the instruments are








C. Notify the Engineer if any installation condition does not meet the instrument





A. Project environmental conditions as specified in Section 17050.

1. Provide instruments suitable for the installed site conditions including, but not limited

to, material compatibility, site altitude, site seismic conditions, humidity, and process

and ambient temperatures.

1.08 WARRANTY


1.09 MAINTENANCE

A. Furnish all parts, materials, fluids, etc. necessary for operation, maintenance, and

calibration purposes throughout the warranty period. Deliver all of these supplies before

project substantial completion.

PRODUCTS

2.01 MANUFACTURERS

A. Mechanical type pressure switch: One of the following or equal:

1. Ashcroft B Series Type 400.

2. United Electric Controls 400 Series.

3. ASCO S-Series.




17403 - 3


A. Mechanical type pressure switches:

1. General:

a. Pressure switch shall be diaphragm or diaphragm-sealed piston type.

2. Performance requirements:

a. Pressure range:

1) As specified in data sheets following this Section.

b. Accuracy:

1) Within 1.0 percent of range.

c. Repeatability:

1) Within 1.0 percent of range.

3. Element:

a. Type: Diaphragm, diaphragm-sealed piston, or bourdon tube.

b. Overpressure:

1) Minimum 130 percent of maximum range pressure without damage to switch

or sensing element.

2) Minimum 400 percent of nominal range without leakage or rupture.

c. Sensing element shall not require ambient temperature compensation.

d. Wetted materials: Stainless steel.

e. Setpoint:

1) Dual.

2) Switch shall activate at setpoint on increasing pressure for high-pressure

alarm applications and on decreasing pressure for low-pressure alarm

applications.

f. Fixed deadband.

g. Switch elements:

1) Snap acting.

2) Single pole-double throw (SPDT) where required.

3) 2 single pole-double throw (SPDT) where required.

4) Hermetically sealed.

5) Rated at 5 A, 125/250 VAC.

6) Manual reset type.

h. Enclosure: Epoxy coated:

1) NEMA Type 4X where required.

2) NEMA Type 7 where required.

i. Switch mounting:

1) Process connection: 1/2-inch NPT.

4. Components:

a. Provide all necessary hardware for pressure switch mounting.




17403 - 4

2.03 ACCESSORIES

A. Pulsation dampeners and snubbers:

1. Provide pulsation dampener or snubber with each pressure switch installed on

discharge of positive displacement type pump.

2. Materials: Stainless steel.

3. Mount pulsation dampener or snubber integrally to the pressure switch.

4. Connection: 1/2-inch NPT.

B. Provide diaphragm seals as specified in data sheets or as indicated on the Drawings and

as specified in Section 17401:

1. Diaphragm seal and pressure switch shall be assembled by manufacturer and

shipped as an assembly.

C. Furnish block and bleed valves as specified in Section 17402.

D. Furnish gauge valves as specified in Section 17402.



B. Factory calibrate each instrument with a minimum 3-point calibration or according to

Manufacturer’s standard at a facility that is traceable to the NIST.

1. Submit calibration data sheets to the Engineer at least 30 days before shipment of

the instruments to the project site.

EXECUTION

3.01 EXAMINATION (NOT USED)

3.02 PREPARATION (NOT USED)

3.03 INSTALLATION



necessary appurtenances including weld-o-lets, valves, etc. for proper installation of

instruments.



3.05 ADJUSTING


instructions:






17403 - 5

3.06 CLEANING





C. Furnish 1 hours of OWNER training.

3.08 PROTECTION


3.09 SCHEDULES


all instruments specified in the Contract Documents:

1. Instruments may be indicated on the Drawings, specified in the Specifications or

both.

END OF SECTION




17403 - 6

A/E: PRESSURE/VACUUM

SWITCHES

Spec. No. Rev.

Contractor: No By Date Revision 17403

Project: Digester 1 and 2 Modifications Contract Date

Customer: Clean Water Services

Plant: Rock Creek AWWTF Req. P.O.

Location: Hillsboro, OR

BOM No.: By Chk App

File:

1 Type Press: Vacuum: Comp.: Diff.Press: Other

D 2 Setting Set in Field: Factory Set: Internal: External: Dial:

E 3 Dead Band Fixed: Adj.: Min.: Other:

V 4 Mtl : Body Seat Tube

I 5 Element Type Diaphragm: Bourdon: Bellows: Other

C 6 Material Bronze: SS: Alloy St.: Other

E 7 Connection ½ in NPT Bottom: Back:

8 Mounting Local: Surface: Flush:

9 Accuracy

10 Other

11 Type Snap:

12 Quantity Single: Dual:

S 13 Form SPST: SPDT: DPDT: Other

W 14 Rating: Amps Volts Hertz 10 120 60

I 15 Other

T 16 Load Inductive: Non-Inductive:

C 17 Enclosure As noted below.

H 18 Enclosure Class

19 Conduit Connection MFR STD: Other

20 Other

21 Manufacturer

22 Model No.

Rev Tag Number Adj. Range SP Process Signal SP Op. Temp. P&ID Service Notes

720PSH7501 0-30 in

H2O 720I102 See Note 1

720PSHL7002 0-60 PSI 720I103 See Note 2




17403 - 7

Notes:

1. Single SPDT, NEMA 7 Enclosure.

2. Double SPDT, NEMA 4X Enclosure

3. Refer to Section 17401 for additional diaphragm seal requirements.

4. Refer to Section 17402 for additional instrument valve requirements.

Durham AWWTF – FOG Tank Retrofit Project Pressure/Vacuum Measurement: Gauges



17404 - 1

SECTION 17404

PRESSURE/VACUUM MEASUREMENT: GAUGES

GENERAL

1.01 SUMARY


1. Pressure/vacuum gauges.


1. The Contract Documents are complementary; what is called for by one is as binding as if

called for by all.


subcontractors, suppliers, and other individuals or entities performing or furnishing any of

Contractor’s Work.

3. The following sections are related to the Work described in this Section. This list of related

sections is provided for convenience only and is not intended to excuse or otherwise diminish

the duty of the Contractor to see that the completed Work complies accurately with the

Contract Documents.


b. Section 17050 - Common Work Results for Process Control and Instrumentation

Systems.

c. Section 17401 - Pressure/Vacuum Measurement: Diaphragm and Annular Seals.

d. Section 17402 - Pressure/Vacuum Measurement: Instrument Valves.

C. Provide all instruments specified in the Contract Documents.

1.02 REFERENCES


B. American Society of Mechanical Engineers (ASME):

1. B40.100 - Pressure Gauges and Gauge Attachments.

1.03 DEFINITIONS


1.04 SUBMITTALS



1. Product data:

a. Accessories such as diaphragm seals, valve manifold, snubbers, and pulsation

dampeners.




17404 - 2



B. Examine the complete set of Contract Documents and verify that the instruments are compatible

with the installed conditions including:





c. Accessories: Verify that all required accessories are provided and are compatible with the

process conditions and physical installation.

C. Notify the Engineer if any installation condition does not meet the instrument manufacturer’s

recommendations or specifications.





1.08 WARRANTY


1.09 MAINTENANCE


PRODUCTS

2.01 MANUFACTURERS

A. Manufacturers: One of the following or equal:

1. Ashcroft:

a. Maximum pressure less than 10 pounds per square inch: Model 1189.

b. Maximum pressure greater than or equal to 10 pounds per square inch: Model1379.

2. Wika.

3. Ametek U.S. Gauge.


A. General:

1. Pressure gauge assembly shall include pressure sensing element, gauge case, and dial

mechanism.




17404 - 3

B. Performance requirements:

1. Pressure range:

a. As specified in the Contract Documents.

2. Accuracy:

a. Grade 2A, as defined by ASME B40.100.

b. Within 1.0 percent of span after friction errors are eliminated by tapping or vibration.

c. Maximum allowable friction inaccuracy: Within 1.0 percent of span.

3. Element:

a. Where the maximum pressure is less than 10 pounds per square inch, provide socket

and bellows; for all other pressure ranges, employ a Bourdon tube.

b. Socket tips for bellows and Bourdon tube:

1) Materials: Type 316 stainless steel.

c. Overpressure: Minimum 130 percent of maximum range pressure without damage to

gauge or sensing element.

d. Wetted materials: Type 316 stainless steel.

4. Dial gauge:

a. Dial size: 4-1/2 inches.

b. Dial case material:

c. Maximum pressure less than 10 pounds per square inch:

1) Aluminum.

d. Maximum pressure greater than or equal to 10 pounds per square inch:

1) Aluminum.

e. Provide safety gauge with safety blow out through the back or top of the unit.

f. Dial face: Gasketed shatterproof glass or polycarbonate.

g. Provide gauge locks on all pressure gauges directly connected to diaphragm seals.

h. Provide gauge locks where possible.

i. Hermetically sealed.

j. Connection and mounting:

1) Direct mounted and suitable for outdoor installation.

2) 1/2 inch NPT.

3) Connection material: Stainless steel.

k. Pointer: Externally adjustable.

2.03 ACCESSORIES

A. Pulsation dampeners and snubbers:

1. Provide pulsation dampener or snubber with each pressure gauge installed on discharge of

positive displacement type pump.

2. Provide piston-type snubber if pressure spikes will exceed 130 percent of gauge maximum

range.

3. Materials: Type 316 stainless steel.

4. Mount pulsation dampener or snubber integrally to the pressure gauge.

5. Connection: 1/2-inch NPT.




17404 - 4

B. Provide diaphragm seals as specified in the Contract Documents and in Section 17401:

1. Diaphragm seal and pressure gauge shall be assembled by manufacturer and shipped as an

assembly.

C. Provide means for gauge isolation as specified in Section 17402:

1. Mount valve manifold integrally to the gauge.

2. Valve manifold and pressure gauge shall be assembled by manufacturer and shipped as an

assembly.



B. Factory calibrate each pressure gauge at a facility that is traceable to the NIST.

C. Provide complete documentation covering the traceability of all calibration instruments.

EXECUTION

3.01 EXAMINATION (NOT USED)

3.02 PREPARATION (NOT USED)

3.03 INSTALLATION



necessary appurtenances including weld-o-lets, valves, etc. for proper installation of instruments.



3.05 ADJUSTING

A. Verify factory calibration of all instruments in accordance with the manufacturer’s instructions:

1. Return factory calibrated devices to the factory if they do not meet the field verification

requirements for calibration.

3.06 CLEANING




B. Demonstrate performance of all instruments to the ENGINEER before commissioning:

C. Furnish 0.5 hours of OWNER training.




17404 - 5

3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all

instruments identified in the Contract Documents:

1. Instruments may be indicated on the Drawings, specified in the Specifications or both.

END OF SECTION




17404 - 6

A/E: PRESSURE

GAUGES

Spec. No. Rev.

Contractor: No By Date Revision 17404

Project: Digester 1 and 2 Modifications Contract Date

Customer: Clean Water Services

Plant: Rock Creek AWWTF Req. P.O.

Location: Hillsboro, OR

BOM No.: By Chk App

File:

1 Type Direct Rdg.: Receiver: Other:

2 Mounting Surface: Local: Flush:

3 Dial Diameter: 4.5” Color:

4 Case Cast Iron: Aluminum: Phenolic: Polished SS Other:

5 Ring Screwed: Hinged: Slip: Std: Other:

6 Blowout Protection None: Disc: Front: Other: Mfr. Std.

7 Lens Glass: Plastic:

8 Options Siphon: N/A Material:

9 Other Snubber:

10 Other Pressure Limit Valve: N/A

11 Other Movement Damping: N/A

12 Nominal Accuracy Required

13 Pressure Element Bourdon: Bellows: Other:

14 Element Material Bronze: Steel: Type SS: 316 Other:

15 Socket Material Bronze: Steel: SS: 316 Other:

16 Connection ¼ in.: ½ in.: Bottom: Other:

17 Movement Dampened: Standard: Other:

18 Diaphragm Seal Mfr.: Wetted Part Mat’l: Type:

19 Other Other Mat’l: Fill Fluid: Model:

20 Manufacturer

21 Model No.

Rev Tag Number Range P&ID Service Notes

720PI6501 720I101

720PI6502 720I101

720PI6607 720I101

720PI6608 720I101

720PI7002 720I103




17404 - 7

Notes:

Refer to Section 17402 for additional instrument valve requirements.

Durham AWWTF – FOG Tank Retrofit Project Control Systems: Panels, Enclosures, and Panel Components



17710 - 1

SECTION 17710|

CONTROL SYSTEMS:

PANELS, ENCLOSURES, AND PANEL COMPONENTS

GENERAL

1.01 SUMMARY


1. Design, fabrication and assembly of all instrumentation enclosures, control panels

and components provided under this contract, including but not limited to:

a. Custom built instrumentation and control panels, including all enclosures for

hand stations controllers, low voltage power distribution, terminal junction boxes,

and marshalling panels.

b. Control panels furnished as part of equipment systems specified in other

Divisions, such as vendor control panels (VCPs) and chemical feed panels.

c. Control components.

d. Control panel installation.












b. Section 01612 - Seismic Design Criteria.

c. Section 16050 - Common Work Results for Electrical.

d. Section 16075 - Electrical Identification.

e. Section 17050 - Basic Measurement and Control Instrumentation Material and

Methods.

C. Provide all instruments identified in Contract Documents.

1.02 REFERENCES


B. Institute of Electrical and Electronics Engineers (IEEE):

1. C62.41.1 – Guide on the Surge Environment in Low-Voltage (1000 V and less) AC

Power Circuits.




17710 - 2

C. Underwriters Laboratories Inc. (UL):

1. 508C - Standard for Industrial Control Equipment.

2. 913 - Standard for Intrinsically Safe Apparatus and Associated Apparatus for Use in

Class I, II, III, Division 1, Hazardous (Classified) Locations.

3. 1283 - Standard for Electromagnetic Interference Filters.

4. 1449 - Standard for Surge Protective Devices.

1.03 DEFINITIONS



1. The term “panel” in this Section is interchangeable with the term “enclosure.”


A. Panel dimensions:

1. Minimum dimensions are scalable from or as indicated on the Drawings and are

based upon manufacturer’s non-certified information. It is the responsibility of the

Contractor or manufacturer to design and size all panels:

a. Size panels to provide space for all equipment, wiring, terminations, and other

items in the panel, including space for future build out.

b. Panel sizes that substantially deviate (within 3 inches in any dimension) from the

sizes indicated on the Drawings must be approved by the Engineer.

c. Maximum panel depth: 30 inches, unless otherwise indicated.

B. Structural design:

1. Completed and installed panel work shall safely withstand seismic requirements at

the project site as specified in Section 16050. Enclosures and internal equipment

shall be braced to prevent damage from specified forces.

1.05 SUBMITTALS

A. Provide submittals as specified in Sections 01330 and 17050.

B. Provide a control panel hardware submittal, for each control panel and enclosure being

provided on this project, including but not limited to:

1. Product data:

a. Enclosure construction details and NEMA type.

b. Manufacturer's literature and specification data sheets for each type of

equipment to be installed within or on the panel or enclosure.

2. Shop drawings:

a. Scaled, detailed exterior panel (front and side views) and interior panel layout

showing equipment arrangement and dimensional information:

1) Provide draft for review and approval by Engineer. The Engineer has the

authority to substantially alter initial panel layouts.

b. Complete nameplate engraving schedule.

c. Structural details of fabricated panels.




17710 - 3

3. Calculations:

a. Provide installation details based on calculated shear and tension forces:

1) Calculations shall be signed and sealed by a Professional Engineer licensed

in the State of Oregon.

b. For assembled enclosures and other equipment with a weight of 200 pounds or

more, provide calculations for:

1) Weight including panel internal components.

2) Seismic forces and overturning moments.

3) Shear and tension forces in connections.

c. Cooling calculations, to include but not limited to:

1) Highest expected ambient temperature for the enclosure's location

2) Internal heat load.

3) Exposure to direct sunlight.

4) Dimensions of the enclosure in inches.

5) Maximum allowable temperature inside the enclosure, based on the lowest

operating temperature limit of the installed components.

4. Bill of material, including quantity, description, manufacturer, part number, serial

number, vendor name with phone, and spare part list with unit price. Bills of material

shall include all items within enclosure.

a. Provide the Bill of material on CD-ROM in Microsoft Excel format.

C. Seismic design:

1. Seismic panel construction:

a. Seismic anchorage: Provide seismic design calculations and installation details

for anchorage of all panels, enclosures, consoles, etc. to meet seismic

requirements in Section 01612:

1) Stamped by a Professional Engineer registered in the State of Oregon.

b. For floor mounted free standing panels weighing 200 pounds or more

(assembled, including contents), submit calculations, data sheets, and other

information to substantiate that panel, base, and framing meet minimum design

strength requirements and seismic requirements as specified in Section 01612.

Calculations shall be signed and sealed by a Professional Engineer licensed in

the state where the cabinets and panels will be installed.



B. Assemble panels, enclosures, and rack systems along with all internal and external

devices, wiring, equipment, and materials in a facility that is recognized by UL to

assemble and certify UL-labeled control panels:

1. Provide all components and equipment with UL 508 listing.

2. All control panels shall be UL 508A labeled, unless the equipment in the panel and

the design in the contract documents cannot be reasonably modified to meet the

requirements for UL 508A labeling:

3. Provide fuses for all equipment that is not UL or UR listed.




17710 - 4

C. Factory Acceptance Test. A Factory Acceptance Test shall be performed to demonstrate

all the functions of the process control system, except the functionality of the application

software provided by Others. The Owner and ENGINEER shall witness the Factory Test.

The test shall include, but not be limited to, the test procedures described below:

1. Panel Inspections:

a. The ENGINEER to inspect each control panel for completeness, workmanship, fit

and finish, and compliance with the Contract Documents and the approved shop

drawings.

b. Provide panel inspection forms as part of the Factory Acceptance Test

procedures submittal.

c. Inspection to include, as a minimum: layout, mounting, wire and data cable

routing, wire tags, power supply, components and wiring, I/O components layout

(including terminals, wiring and relays), device layout on doors and front panels,

and proper ventilation operation.

d. The Contractor shall have a complete set of approved shop drawings available for

this inspection.

2. I/O Test:

a. Verify that I/O is properly wired to field terminals and is properly mapped into the

PLC and the rest of the SCADA system, including all operator interface devices.

b. Test Methodology:

1) Discrete inputs: Apply appropriate input at panel terminal and observe the

following:

a) input card indicator

b) data value at each indicated data address

c) data received on all operator interface displays (SCADA workstations and

local operator interface (LOI) displays).

2) Discrete outputs: Issue commands from operator interface screen verify

output card indicator light and measure response at field wiring terminals.

3) Analog inputs: Apply appropriate analog input signal at panel terminals,

observe data value at each indicated data address, and observe data

properly received at each operator screen. Check each point at 0 percent, 50

percent, and 100 percent of scale.

4) Analog outputs: Enter scaled values in the output buffer file, observe the

output data file value, and measure appropriate response at panel wiring

terminals.

c. Test forms to include, but not be limited to:

1) PLC and panel number.

2) I/O Type.

3) I/O tag name.

4) Panel terminal block numbers.

5) Rack/slot/number of I/O point.

6) Check-off for correct response for each I/O point.

7) Space for comments.

8) Initial of individual performing test.

9) Date test was performed.

10) Witness’ signature lines.




17710 - 5


A. Project environmental conditions as specified in Section 17050.

1. Provide instruments suitable for the installed site conditions including, but not limited

to, material compatibility, site altitude, site seismic conditions, humidity, and process

and ambient temperatures.



1.09 WARRANTY


PRODUCTS

2.01 MANUFACTURERS

A. As listed below in the individual component paragraphs.

B. Provide instruments and other components performing similar functions of the same

type, model, or class, and from 1 manufacturer.

2.02 EXISTING PRODUCTS

A. Provide labor and materials for complete modifications to existing panels as required.

B. Field cut and refinish existing panel faces to original condition to accommodate

installation of new instruments, removal of existing instruments and fitting of blanks to

suit new layouts. New instrument supports shall be provided as required for complete

installation.

2.03 MATERIALS

A. Construct and finish enclosures using materials capable of withstanding the mechanical,

electrical, and thermal stresses, as well as the effects of humidity and corrosion that are

likely to be encountered in normal service:

1. Enclosures shall have the following properties:

a. NEMA Type 4: Steel with gasketed door, rain tight.

b. NEMA Type 4X: Type 316 stainless steel (unless indicated Type 304 on the

drawings)

B. Bolting material:

1. Commercial quality 1/2-inch diameter, stainless steel hex-head grade 5 bolts, nuts

and washers, with unified coarse (UNC) threads.

2. Carriage bolts for attaching end plates.

3. All other bolted joints shall have S.A.E. standard lock washers.




17710 - 6


A. Panels/enclosures:

1. Manufacturers: One of the following or equal:

a. Rittal.

b. Hoffman Engineering.

c. Saginaw Control & Engineering.

2. Panel assembly:

a. General guidelines for panel fabrication include:

1) Continuous welds ground smooth.

2) Exposed surfaces free of burrs and sharp edges.

3) Base formed of heavy channel iron, either galvanized or powder coated,

minimum 1/2 inch holes at 12 inch spacing to accommodate anchoring of

freestanding enclosures to floor.

b. Construct enclosure and mounting panel using stretcher level quality sheet metal

having minimum thickness not less than the following sizes (U.S. Standard

Gauge):

1) Use heavier sheet metal to meet seismic requirements at the project site or

when required due to equipment requirements.

Enclosure Height

(inches)

Minimum Enclosure Steel Thickness

(gauge)

Minimum Back Mounting Panel

Thickness

(gauge)

Up to 57 12 12

57 - 69 12 10

69 - 82 12, except 10 on back 10

82 or more 10 10

c. Construct supporting frame structure with angled, channeled, or folded rigid

section of sheet metal, rigidly attached to and having essentially the same outer

dimensions as the enclosure surface and having sufficient torsional rigidity to

resist the bending moments applied via the enclosure surface when it is

deflected.

d. Provide stiffeners for back mounting panels in enclosures larger than 4 feet. In

addition, secure the panels in place by collar studs welded to the enclosure.

e. Door construction:

1) Turned-back edges suitably braced and supported to maintain alignment and

rigidity without sagging.

2) Sufficient width to permit door opening without interference with rear

projection of flush mounted instruments.

3) Heavy gauge piano type continuous stainless steel hinges.

4) For NEMA Type 4 and Type 4X, provide oil resistant neoprene sealing gasket

and adhesive to seal cover to enclosure.

5) Gasket installed to seal against roll lip on the enclosure opening.




17710 - 7

f. Latches:

1) For panels each door provided with a 3-point latching mechanism and locking

handle with rollers on the ends of the latch rods. Latch rods connected to a

common door handle, hold doors securely, forming a compressed seal

between door and gasket, at the top, side, and bottom.

a) Provide padlock for each enclosure with padlock provisions.

2) Include an oil-tight key-locking, 3-point latching mechanism on each door:

a) Provide 2 keys per panel.

b) All locks keyed alike.

3) For large type NEMA Type 4 and NEMA Type 4X cabinets, not available with 3-

point latching hardware, provide multiple clips and padlock hasps.

4) Provide quick release latches for all NEMA Type 4 and Type 4X enclosures.

g. Panel cut-outs:

1) Cut, punch, or drill cutouts for instruments, devices, and windows. Smoothly

finish with rounded edges.

2) Allow a minimum of 3-inch envelope around all displays, controllers, and

monitors.

3) Reinforce around cut-outs with steel angles or flat bars for the following:

a) Large panel cutouts; for example, openings for local operator interfaces.

b) Pilot device groupings, where the removed metal exceeds 50 percent of

the available metal.

3. In addition to the requirements specified above the following requirements for NEMA

Type 4X powder coated stainless steel enclosures apply:

a. Minimum 14 gauge, Type 304 stainless steel.

b. Captive stainless steel cover screws threaded into sealed wells.

c. Inside finish: White polyester powder coating.

d. Specifically designed for use with flange-mounted disconnect handles where

required or as indicated on the Drawings.

e. NEMA Type 4X powder coated stainless steel enclosures are not an acceptable

substitute for stainless steel.

4. Outdoor panels. Supplementary requirements for panels located outdoors are as

follows:

a. All enclosures located outdoors shall be explicitly designed and rated for outdoor

service by the manufacturer.

b. Door hardware: stainless steel.

c. Provide rain canopy and sun shield.

d. Bases: Heavy channel, gasketed stainless steel bases, flanges up, for anchoring

to pad.

B. Arrangement of components:

1. Arrange panel internal components for external conduit and piping to enter into panel

either from above or below.

2. Arrange panel instruments and control devices in a logical configuration associating

pushbutton and selector switches with related readout devices, or as indicated on

the Drawings.




17710 - 8

3. Mount internal control components on an internal back-panel. Devices may be

mounted on the side-panel only by special permission from the Engineer.

4. All control panel mounted operator interface devices shall be mounted between 3

feet and 5 feet above finished floor.

C. Overcurrent protection:

1. Main overcurrent device:

a. Where the electrical power supply voltage to the control panel is more than 120

VAC, provide the panel with a flange mounted disconnect handle operating a

molded case circuit breaker, and provide a control power transformer for 120

VAC circuits:

1) Door-mounted disconnect handles are not acceptable.

2) Mechanically interlocked the disconnect switch with the control enclosure

doors so that no door can be opened unless the power is disconnected, and

the disconnect switch cannot be closed until all doors are closed.

3) Provide means to defeat the interlock.

4) Lockable in the off position.

b. Control panels supplied with 120 VAC:

1) Provide an internal breaker with the line side terminals covered by a barrier.

2) Provide a nameplate prominently positioned on the control panel identifying

the location of the power source and a warning statement requiring the

source to be disconnected before opening the door to the enclosure.

2. Selection and ratings of protective devices:

a. Interrupting ratings: Not less than the system maximum available fault current at

the point of application.

b. Voltage rating: Not less than the voltage of the application.

c. Select current rating and trip characteristics to be suitable for:

1) Maximum normal operating current.

2) Inrush characteristics.

3) Coordination of the protective devices to each other and to the source

breaker feeding the panel.

3. Provide a separate protective device for each powered electrical device:

a. An individual circuit breaker for each 120 VAC instrument installed within its

respective control panel and clearly identified for function.

b. An individual fuse for each PLC discrete output. Provide with individual blown

fuse indication external of the I/O card:

1) Size external fuse to open before any I/O card mounted fuses.

c. An individual 5-ampere fuse for each discrete input loop.

d. An individual 1/2-ampere fuse for each 4 to 20 milliamperes analog loop

powered from the control panel.

e. Install protective devices on the back mounting panel and identify by a service

nameplate in accordance with the wiring diagrams.

4. Fuses for 4 to 20 milliamperes signals:

a. Provide durable, readily visible label for each fuse, clearly indicating the correct

type, size, and ratings of replacement fuse:

1) Label shall not cover or interfere with equipment manufacturer's instructions.




17710 - 9

b. Provide fuses rated for the voltage and available short circuit current at which

they are applied.

c. Manufacturer: One of the following or equal:

1) Ferraz Shawmut.

2) Littelfuse.

3) Bussmann.

5. Fuse holders:

a. Modular type:

1) DIN rail mounting on 35 millimeters rail.

2) Touch safe design: All connection terminals to be protected against

accidental touch.

3) Incorporates blown fuse indicator.

b. Provide nameplate identifying each fuse:


c. Manufacturer: One of the following or equal:

1) Phoenix Contact.

2) Allen-Bradley 1492-FB Series B.

6. Control circuit breakers:

a. DIN rail mounting on 35 millimeters rail.

b. Manual OPEN-CLOSE toggle switch.

c. Rated 250 VAC.

d. Interrupting rating: 10 kiloampere (kA) or available fault current at the line

terminal, whichever is higher.

e. Current ratings: As indicated on the Drawings or as required for the application.

f. Provide nameplate identifying each circuit breaker:



1) Phoenix Contact.

2) ABB.

3) Allen-Bradley Series.

4) Square D.

D. Conductors and Cables:

1. Power and Control Wiring:

a. Materials: Stranded, soft annealed copper.

b. Insulation: 600V type MTW.

c. Minimum Sizes:

1) Primary power distribution: 12 AWG.

2) Secondary power distribution: 14 AWG.

3) Control: 16 AWG.

d. Color:

1) BLACK, RED – 120/240VAC Single Phase (line and load) conductors.

2) RED – 120 VAC conductors within control panel (Discrete Input & Output)




17710 - 10

3) ORANGE – 120V control conductors internal to the control panel.

4) YELLOW - 120V conductors external to the control panel.

5) GREEN - Ground wire.

6) WHITE - 120V Neutral conductors.

7) A-Brown, B-Orange, C-Yellow – 277/480V three phase conductors.

8) GRAY - 277 Neutral conductors.

9) BLUE - DC positive conductors.

10) WHITE with BLUE stripe - DC negative (grounded) conductors.

2. Signal Cables, Twisted Shielded:

a. Materials: Stranded, soft annealed copper.

b. Insulation: 600V, PVC outer jacket.

c. Minimum Size: 16 AWG paired/triad.

d. Overall aluminum shield (tape).

e. 20 AWG seven-strand tinned copper drain wire.

f. Color:

1) 2 Conductor:

a) Positive (+): WHITE.

b) Negative (-): BLACK.

2) 3 Conductor:

a) Positive (+): WHITE.

b) Negative (-): RED.

c) Signal: BLACK.

g. Insulate the foil shielding and exposed drain wire for each signal cable with heat

shrink tubing.

E. Conductor identification:

1. Identify each conductors and cables with unique wire numbers as specified in

Section 16075.

2. Readily identified without twisting the conductor.

F. General wiring requirements:

1. Wiring methods: Wiring methods and materials for panels shall be in accordance with

the NEC requirements for General Purpose (no open wiring) unless otherwise

specified.

2. Install all components in accordance with the manufacturer’s instructions included in

the listing and labeling.

3. Provide a nameplate on the cover of the control panel identifying all sources of power

supply and foreign voltages within the control panel.

4. Provide transformers, protective devices, and power supplies required to convert the

supply voltage to the needed utilization voltage.

5. Provide power surge protection for all control panels.

6. Provide signal surge protection within control panels for each analog I/O, discrete I/O

and data line (Copper Ethernet, Coax, Fieldbus signals) that originates from outdoor

devices.




17710 - 11

7. Provide nonmetallic ducts for routing and organization of conductors and cables:

a. Size ducts for ultimate build-out of the panel, or for 20 percent spare, whichever

is greater.

b. Provide separate ducts for signal and low voltage wiring from power and 120 VAC

control wiring:

1) 120 VAC: Grey colored ducts.

2) 24 VDC: White colored ducts.

8. Cables shall be fastened with cable mounting clamps or with cable ties supported by

any of the following methods:

a. Screw-on cable tie mounts.

b. Hammer-on cable tie mounting clips.

c. Fingers of the nonmetallic duct.

9. The free ends of cable ties shall be cut flush after final adjustment and fastening.

10. Provide supports at the ends of cables to prevent mechanical stresses at the

termination of conductors.

11. Support panel conductors where necessary to keep them in place.

12. Conductors and cables shall be run from terminal to terminal without splice or joints.

Exceptions:

a. Factory applied connectors molded onto cables shall be permitted. Such

connectors shall not be considered as splices or joints.

13. The control panel shall be the source of power for all 120 VAC devices

interconnected with the control panel including, but not limited to:

a. Solenoid valves.

b. Instruments both mounted in the control panel and remotely connected to the

control panel.

2.05 COMPONENTS

A. Thermal management:

1. Provide heating, cooling, and dehumidifying devices in order to maintain all

instrumentation and control devices to within a range as specified in Section 17050.

2. Heating:

a. Provide all panels located in areas that are not climate controlled with

thermostatically controlled strip heaters; except, where all of the following

conditions apply:

1) The panel is not supplied with 120 VAC power.

2) There are no electronics or moisture-sensitive devices in the enclosure.

3) The panel is smaller than 38 inches high.

3. Heat exchanger:

a. Closed-loop design ensuring separation of ambient air and clean air inside the

cabinet.

b. Filterless design to facilitate easy cleaning of the core.

c. Mounting: Indicated on the Drawings.

4. Enclosure temperature sensor as indicated on the Drawings:




17710 - 12

5. Enclosure temperature switch:

a. Provide wall mount bimetallic switch transmitter (to measure internal cabinet

temperature in all enclosures) containing electrical components such as PLCs,

RTUs, RIO, and VFDs.

b. Sensor and electronic enclosure.

c. Accuracy: Within 2.0 degrees Fahrenheit.

d. Manufacturer: The following or equal:

1) Hoffman ATEMNC.

6. Fan ventilation:

a. Temperature control switch and alarm:

1) Power: 120 VAC.

2) Bimetallic temperature senor.

3) Adjustable setpoint range 30 degrees Fahrenheit to 140 degree Fahrenheit.

4) Hoffman ATEM series or equal.

B. Panel meters.

C. Pilot devices:

1. General:

a. Provide operator pushbuttons, switches, and pilot lights, from a single

manufacturer.

b. Size:

1) 30.5 millimeters.

c. Heavy duty.

d. Pushbuttons:

1) Contacts rated:

a) NEMA Type A600.

2) Furnish 1 spare normally open and normally closed contact with each switch.

e. Selector switches:

1) Contacts rated:

a) NEMA Type A600.

b) Knob type:

2) Furnish 1 spare normally open contact and normally closed contact with each

switch.

3) Provisions for locking in the OFF position where lockout provisions are


f. Pilot lights:

1) Type:

a) LED.

2) Push to test.

3) Lamp color:

a) On/Running/Start: Red.

b) Off/Stop: Green.

c) Power: White.




17710 - 13

d) Alarm: Amber.

e) Status or normal condition: White.

f) Opened: Red.

g) Closed: Green.

h) Failure: Amber.

2. Indoor and outdoor areas:

a. NEMA Type 4/13.

b. Manufacturer: One of the following or equal:

1) Allen-Bradley Type 800T.

2) Square D Class 9001 Type K.

3) General Electric Type CR104P.

4) IDEC TWTD.

3. Corrosive areas:

a. NEMA Type 4X.

b. Corrosion resistant.

c. Exterior parts of high impact strength fiberglass reinforced polyester or multiple-

layer epoxy coated zinc.

d. Manufacturer: One of the following or equal:

1) Cutler Hammer Type E34.

2) Square D Class 9001 Type SK.

3) Allen-Bradley Type 800H.

4) IDEC TWTD.

4. Hazardous (Classified) Areas/Class I Division 2:

a. NEMA Type 4X.

b. Corrosion resistant.

c. Exterior parts of high impact strength fiberglass reinforced polyester or multiple-

layer epoxy coated zinc:

1) All contacts contained within a hermetically sealed chamber:

a) Pushbuttons.

b) Selector switches.

c) Push-to-test contacts on pilot lights.

2) UL listed and labeled for Class I Division 2 areas.

d. Manufacturer: One of the following or equal:

1) Cutler Hammer Type E34.

2) Allen-Bradley Type 800H.

D. Potentiometer and slidewire transmitters:

1. Provide a DC output in proportion to a potentiometer input.

2. Potentiometer input:

a. 100 ohms to 100 K ohms.

b. Impedance Greater or equal to 1 M ohms.

c. Zero turn-up: 80 percent of full scale input.

d. Span turn-down: 80 percent of full scale input.




17710 - 14

3. Field configurable output:

a. Voltage and current: All conventional current loops and voltage control signals.

4. Accuracy including linearity and hysteresis within 0.1 percent max at

25 degrees Celsius.

5. Operating temperature: 0 degrees Celsius to 55 degrees Celsius.

6. Supply power: 9 to 30 VDC.

7. Manufacturer: The following or equal:

a. Phoenix Contact.

E. Signal isolators and converters:

1. Furnish signal isolators that provide complete isolation of input, output, and power

input:

a. Minimum isolation level: 1.5 kilovolts AC/50 hertz for at least 1 minute.

b. Adjustable span and zero.

c. Accuracy: Within 1.0 percent of span.

d. Ambient temperature range: -20 degrees Celsius to +65 degrees Celsius.


a. Phoenix Contact MCR Series.

b. Acromag 1500, 600T, 800T, Flat Pack or ACR Series.

c. Action Instruments Q500 Series or Ultra SlimPakII.

d. AGM electronics Model TA-4000.

F. Relays:

1. General:

a. For all types of 120 VAC relays, provide surge protection across the coil of each

relay.

b. For all types of 24 VDC relays, provide a free-wheeling diode across the coil of

each relay.

2. General purpose:

a. Magnetic control relays.

b. NEMA Type A300 rated:

1) 300 volts.

2) 8 Amps continuous (minimum).

3) 7,200 volt-amperes make.

4) 720 volt-amperes break.

c. Plug-in type.

d. LED indication for energization status.

e. Coil voltages: As required for the application.

f. Minimum poles: DPDT.

g. Touch safe design: All connection terminals to be protected against accidental

touch.

h. Enclose each relay in a clear plastic heat and shock-resistant dust cover.

i. Quantity and type of contact shall be as indicated on the Drawings or as needed

for system compatibility.




17710 - 15

j. Relays with screw-type socket terminals.

k. Provide additional (slave/interposing) relays when the following occurs:

1) The number or type of contacts shown exceeds the contact capacity of the

specified relays.

2) Higher contact rating is required in order to interface with starter circuits or

other equipment.

l. DIN rail mounting on 35 millimeters rail.

m. Ice cube type relays with retainer clips to secure relay in socket.

n. Integrated label holder for device labeling.

o. Manufacturer: One of the following or equal:

1) Phoenix Contact PLC series.

2) Potter and Brumfield Type KRP or KUP.

3) IDEC R* series. (* = H, J, R, S, U).

4) Allen-Bradley Type 700 H Series.

5) Square D Type K.

3. Latching:

a. Magnetic latching control relays.

b. NEMA Type B300 rated:

1) 300 volts.

2) 10 Amps continuous.



c. Plug-in type.

d. DIN rail mounting on 35 millimeters rail.

e. Coil voltage: As required for the application.

f. Minimum poles: 2PDT; as required for the application. Plus 1 spare pole.

g. Touch safe design: All connection terminals to be protected against accidental

touch.

h. Clear cover for visual inspection.

i. Provide retainer clip to secure relay in socket.

j. Manufacturer: One of the following or equal:

1) Square D type 8501 Type K.

2) IDEC TWTD.

4. Time delay:

a. Provide time delay relays to control contact transition time.

b. Contact rating:

1) 240 volts.

2) 10 Amps continuous.



c. Coil voltage: as required for the application.




17710 - 16

d. Provide pneumatic or electronic type with on-delay, off-delay, and on/off delay:

1) For off delay use true power off time delay relays. Where the required timing

range exceeds capability of the off delay relay use signal off delay where

power loss will not cause undesirable operation or pneumatic time delay

relays.

e. Minimum poles: 2PDT.

f. Units include adjustable dial with graduated scale covering the time range in

each case.

g. Minimum timing range: 0.1 seconds to 10 minutes, or as required for the

application.

h. Manufacturer: One of the following or equal:

1) IDEC RTE series.

2) Agastat type Series 7000 series (pneumatic).

3) Allen-Bradley type 700HR Series.

G. Terminal blocks:

1. Din rail mounting on 35 mm rail.

2. Suitable for specified AWG wire.

3. Rated for 15 amperes at 600 volts.

4. Screw terminal type.

5. Provide mechanism to prevent wire connection from loosening in environments

where vibration is present. This mechanism shall not cause permanent deformation

to the metal body.

6. Finger safe protection for all terminals for conductors.

7. Construction: Polyamide insulation material capable of withstanding temperature

extremes from - 40 degree Celsius to 105 degrees Celsius.

8. Terminals: Plainly identified to correspond with markings on the diagrams:

a. Permanent machine printed terminal identification.

9. Disconnect type field signal conductor terminals with socket/screw for testing.

10. Identify terminals suitable for use with more than 1 conductor.

11. Position:

a. So that the internal and external wiring does not cross.

b. To provide unobstructed access to the terminals and their conductors.

12. Provide minimum 25 percent spare terminals.


a. Phoenix Contact UK5 Series.

b. Allen-Bradley Series 1492.

14. Wire duct:

a. Provide flame retardant plastic wiring duct, slotted with dust cover.

b. Type:

1) Wide slot.

2) Narrow slot.

3) Round hole.




17710 - 17

c. Manufacturer: The following or equal:

1) Panduit.

H. Surge protection devices:

1. Control panel power:

a. 120-volt control power source: Non-UPS powered:

1) Provide surge protection device (SPD) for panel power entrances:

a) Nominal 120 VAC with a nominal clamping voltage of 200 volts.

b) Non-faulting and non-interrupting design.

c) A response time of not more than 5 nanoseconds.

2) Control panel power system level protection, non-UPS powered:

a) Design to withstand a maximum 10 kA test current of a 8/20 µs

waveform according to IEEE C62.41.1Category C Area.

b) For panels receiving power at 120 VAC, provide surge protection at

secondary of main circuit breaker.

c) Provide both normal mode noise protection (line to neutral) and common

mode (neutral to ground) surge protection.

d) DIN rail mounting.

e) Attach wiring to the SPD by means of a screw type cable-clamping

terminal block:

(1) Gas-tight connections.

(2) The terminal block: Fabricated of non-ferrous, non-corrosive

materials.

f) Visual status indication of MOV status on the input and output circuits.

g) Dry contact rated for at least 250 VAC, 1 Amp for remote status

indication.

h) Meeting the following requirements:

(1) Response time: Less than or equal to 100 ns.

(2) Attenuation: Greater than or equal to -40 dB at 100 kilovolt-hertz as

determined by a standard 50 ohms insertion test.

(3) Safety approvals:

(a) UL 1283 (EMI/RFI Filter).

(b) UL 1449 2nd Edition.

i) Manufacturer: One of the following or equal:

(1) Phoenix Contact type SFP TVSS/Filter.

(2) Liebert Accuvar series.

(3) Islatrol.

b. 120-volt control power source: UPS powered.

1) Provide surge protection on the control power source at each panel

containing power supplies, or electronic components including PLCs, I/O,

HMI, and digital meters.




17710 - 18

2) Location:

a) For panels with a UPS, install surge protection ahead of UPS and

maintenance bypass switch.

(1) Surge protection is not required for 120 VAC circuits that are only

used for panel lights and receptacles.

b) For panels receiving power at 480 VAC, provide surge protection on the

120 VAC control power transformer secondary.

3) MCOV: 150 VAC.

4) Surge capability (8/20 microsecond wave): 10 kA.

5) Peak let-through: 620V L-N, 850V L-G.


a) Phoenix Contact Plugtrab PT series

b) MTL Surge Technologies MA15 series

2. Instrument, data and signal line protectors (traditional I/O) – panel mounted:

a. Surge protection minimum requirements: Withstand a 10 kA test current of a

8/20 µs waveform in accordance with IEEE C62.41.1 Category C Area.

b. DIN rail mounting on 35 millimeters rail (except field mounted SPDs).

c. SPDs consisting of 2 parts:

1) A base terminal block.

2) A plug protection module:

a) Replacing a plug shall not require the removal of any wires nor interrupt

the signal.

b) Base and plug coded to accept only the correct voltage plug.

d. SPD Manufacturer: One of the following or equal:

1) Phoenix Contact Plugtrab Series.

2) Bournes Series 1800.

3. Instrument, data and signal line protectors (traditional I/O)– field mounted:

a. Surge protection minimum requirements: Withstand a minimum 10 kA test

current of a 8/20 µs waveform in accordance with IEEE C62.41.1 Category C

Area.

b. Manufacturer: One of the following or equal:

1) Plugtrab PT Series

2) MTL TP48 Series.

I. Power supplies:

1. Design power supply systems so that either the primary or backup supply can be

removed, repaired, and returned to service without disrupting the system operation.

2. Convert 120 VAC to 24 volt DC or other DC voltages required or as required for the

application.

3. Provide backup 24 VDC power supply units to automatically supply the load upon

failure of the primary supply.

4. Provide power supply arrangement that is configured with several modules to supply

adequate power in the event of a single module failure:

a. Provide Automatic switchover upon module failure.

b. Alarm contacts monitored by the PLC.




17710 - 19

5. Sized to provide 40 percent excess rated capacity.

6. UL 508C listed to allow full rated output without de-rating.

7. Provide fuse or short-circuit protection.

8. Provide a minimum of 1 set of dry contacts configured to change state on failure for

monitoring and signaling purposes.

9. Output regulation: Within 0.05 percent for a 10 percent line change or a 50 percent

load change:

a. With remote voltage sensing.

10. Operating temperature range: 0 degrees Celsius to 50 degrees Celsius.

11. Touch safe design: All connection terminals to be protected against accidental touch.

12. DIN rail mounting on 35 millimeters rail.

13. Provide self-protecting power supplies with a means of limiting DC current in case of

short circuit.


a. Phoenix Contact Quint series.

b. IDEC PS5R series.

c. Sola.

d. Acopian.

e. PULS.

J. Intrinsic safety barriers:

1. Transformer isolated barrier:

a. Containing a transformer to provide complete:

1) Isolation between the safe and hazardous areas for loop powered devices.

2) 3-way isolation between the safe area, hazardous area and power supply

powered devices.

b. Resistor for current limitation.

c. Fuses for short circuit protection.

d. Provide barriers with pluggable connectors that are coded for easy replacement.

e. Transmission error shall be less than or equal to 0.1 percent of full scale.

f. DIN rail mounted on 35 millimeters DIN rail.

g. Approvals:

1) FM.

2) UL 913.

2. Types:

a. Switch isolators:

1) Designed and approved for use with discrete inputs.

2) Supply power: 20 to 30 VDC.

3) Output to track input.

4) LED in the cover to indicate the status of the input.

5) Selector switch to change the logic of the input.

6) Input: Dry contact.

7) Output: SPDT relay.




17710 - 20

b. Transmitter and converters for use with 4 to 20 milliamperes signals without

Hart® communications capability:

1) Designed and approved for use with 4 to 20 milliamperes analog signals.

2) Designed for powering 2 and/or 3 wire transmitters in hazardous locations

and repeating and/or generating the current to the safe area.

3) Supply voltage: 20 to 30 VDC.

c. Transmitter and converters for use with 4 to 20 milliamperes signals with Hart®

communications capability:

1) Designed and approved for use with 4 to 20 milliamperes analog signals.

2) Designed for powering 2 and/or 3 wire transmitters in hazardous locations

and repeating and/or generating the current to the safe area.

3) Transfer digital signals from the hazardous area to the safe area.

4) Complete bi-directional communication between a smart transmitter located

in the field and the suitable equipment located in the safe area.

5) Supply voltage: 20 to 30 VDC.


a. Phoenix Contact ME Series.

b. Pepperl + Fuchs.

K. (NOT USED).

L. (NOT USED).

M. Limit switches:

1. NEMA Type 4X.

2. AC contact rating 120 volts, 10 A.

3. DC contact rating 125 volts, 0.4 A.

4. Provide robust actuation mechanism not prone to degradation.

5. Provide complete actuator mechanism with operating lever and all required

hardware.

6. Allows for contact opening even during contact weld condition.

7. UL approved.

8. Operating temperature range: -18 degrees to +110 degrees Celsius (0 degrees to

230 degrees Fahrenheit).


a. Allen-Bradley 802.

b. Honeywell HDLS.

c. Omron D4.

d. Eaton E47, E49, E50.

e. ABB equal.

N. Current Switches:

a. Operate from 120 VAC supply voltage.

b. 1 normally open and normally closed contacts.




17710 - 21

c. Adjustable current setting.

d. Manufacturer:

1) Zelio RM35.

O. Isolation Transformer:

1. An isolation transformer shall be provided for all control panels as indicated on the

Drawings.

a. Minimum size: 3kVA.

b. Shielded.

c. Low noise.

d. Mounted outside of the control enclosure when indicated on the Drawings.

2. The panel lights, convenience receptacle and environmental controls shall not be

powered from the isolation transformer.

3. Manufacturer: One of the following:

a. Acme T-3-53043-S.

b. General Electric equivalent.

c. Jefferson equivalent.

P. Ethernet switches:

1. Unmanaged Ethernet Switches:

a. Manufacturers - One of the following:

1) Phoenix Contact 2891673.

2) Cisco equivalent.

3) N-Tron equivalent.

4) Approved equal.

b. Properties:

1) Power supply:

a) Provide redundant power supplies.

b) 24 VDC power supply.

c) Alarm output indicating loss of power supply.

2) Performance:

a) 10/100/1000, Full/half-Duplex.

b) MDI/MDI-X Auto-sensing.

3) Environment:

a) Operating Temperature Range: -13 to 167 Degrees Fahrenheit.

b) Humidity: 15 to 95 percent, non-condensing.

4) Connector type:

a) Copper: RJ-45.

5) Mounting:

a) Din Rail.




17710 - 22

2.06 ACCESSORIES


B. Provide panels with an inside protective pocket to hold the panel Drawings. Ship panels

with 1 copy of accepted Shop Drawings including, but not limited to, schematic diagram,

connection diagram, and layout drawing of control wiring and components in a sealed

plastic bag stored in the panel drawing pocket.

C. Provide 15 inch floor stands or legs where needed or as indicated on the Drawings.

D. Provide a folding shelf for enclosures that contain programmable controllers. The shelf

shall be mounted on the inside surface of the door, capable of supporting a laptop

computer.

E. Provide nameplate to each panel as indicated on the Drawings:

1. Provide as specified in Section 16075 on all internal and external instruments and

devices.

2. Provide a nameplate with the following markings that is plainly visible after

installation:

a. Manufacturer’s name, trademark, or other descriptive marking by which the

organization responsible for the panel can be identified.

b. Supply voltage, phase, frequency, and full-load current.

c. Power Source or Circuit ID.

d. Short-circuit current rating of the panel based on one of the following:

1) Short-circuit current rating of a listed and labeled assembly.

2) Short-circuit current rating established utilizing an approved method.

3. Provide enclosures with a flange mounted disconnect that is interlocked with the

doors.

F. Provide a window kit where indicated on the Drawings. The window shall meet the

following requirements:

1. Safety plate glass.

2. Secured by rubber locking seal.

3. Allow full viewing of devices issuing visual process data or diagnostics.

G. Lighting:

1. Provide an LED luminaire within enclosures and control panels.

2. Luminaire shall be Lithonia CLX LED strip luminaire, or equal. Provide flat lens,

80 CRI, 2,500 lumens / ft. Provide a Wattstopper infrared motion sensor on each

luminaire. Sensor shall be rated for damp locations.

a. Enclosures that are 6-feet wide shall be provided with a 4-ft luminaire.

b. Enclosures that are 4-feet wide shall be provided with a 3-ft luminaire.

c. Enclosures that are 3-feet wide shall be provided with a 2-ft luminaire.




17710 - 23

H. Receptacles:

1. Provide 1 duplex receptacle located every 4 feet of enclosure width, spaced evenly

along the back mounting panels.

2. GFCI, 125-volt, single-phase, 15-amp style plug.

3. Provide circuit breaker or fuse to limit receptacle draw to 5 amperes.

I. Grounding:

1. Provide the following:

a. Grounding strap between enclosure doors and the enclosure.

b. Equipment grounding conductor terminals.

c. Provide equipment ground bus with lugs for connection of all equipment

grounding wires.

d. Bond multi-section panels together with an equipment grounding conductor or an

equivalent grounding bus.

2. Identify equipment grounding conductor terminals with the word “GROUND,” the

letters “GND” or the letter “G,” or the color green.

3. Signal (24 VDC) Grounding: Terminate each drain wire of a signal (shielded) cable to

a unique grounding terminal block, or common ground bus at the end of the cable as

shown on the Loop Drawings.

4. Ensure the continuity of the equipment grounding system by effective connections

through conductors or structural members.

5. Design so that removing a device does not interrupt the continuity of the equipment

grounding circuit.

6. Provide an equipment-grounding terminal for each incoming power circuit, near the

phase conductor terminal.

7. Size ground wires in accordance with NEC and UL Standards, unless noted otherwise.

8. Connect all exposed, noncurrent-carrying conductive parts, devices, and equipment

to the equipment grounding circuit.

9. Connect the door stud on the enclosures to an equipment-grounding terminal within

the enclosure using an equipment-bonding jumper.

10. Bond together all control panels both remote and local, processor racks, and

conductive enclosures of power supplies and connect to the equipment grounding

circuit to provide a common ground reference.

J. Provide sunshades for outdoor installations.

2.07 FINISHES

A. Finishes:

1. Metallic (non-stainless):

a. Metal surfaces of panels shall be prepared by chemical cleaning and mechanical

abrasion in accordance with the finish manufacturer’s recommendations to

achieve a smooth, well-finished surface.

b. Scratches or blemishes shall be filled before finishing. One coat of zinc

phosphate shall be applied per the manufacturer’s recommended dry film

thickness, and allowed to dry before applying the finish coat.




17710 - 24

c. Finish coat shall be a baked polyester urethane powder, aliphatic air-dry

polyurethane, or epoxy enamel to meet NEMA rating specified application.

d. Exterior of enclosures located outdoors shall be UV resistant polyester powder

coating. Total dry film thickness shall be 3 mils, minimum.

2. Stainless steel:

a. Stainless enclosures shall be provided with a number 4 brushed finish - not

painted.

B. Colors:

1. Exterior color of panels mounted indoors shall be manufacturer’s standard light gray.

2. Exterior of panels mounted outdoors shall be manufacturer’s standard white.

3. Panel interiors shall be manufacturer’s standard white.


A. As specified in 17050.

B. Factory calibrate each instrument with a minimum 3-point calibration or according to

manufacturer’s standard at a facility that is traceable to the NIST.

1. Submit calibration data sheets to the Engineer at least 30 days before shipment of

the instruments to the project site.

EXECUTION

3.01 EXAMINATION

A. Examine the installation location for the instrument and verify that the instrument will

work properly when installed.

1. Notify the Engineer promptly if any installation condition does not meet the

instrument manufacturer’s recommendations or specifications.

3.02 INSTALLATION

A. Install enclosures so that their surfaces are plumb and level within 1/8 inch over the

entire surface of the panel; anchor securely to wall and structural supports at each

corner, minimum. Direct attachment to dry wall is not permitted.

B. Install the enclosure per guidelines and submitted installation instructions to meet the

seismic requirements at the project site.

C. Provide floor stand kits for wall-mount enclosures larger than 48 inches high.

D. Provide 3-1/2 inch high concrete housekeeping pads for free-standing enclosures.

E. Install gasket and sealing material under panels with floor slab cutouts for conduit:

1. Undercoat floor mounted panels.

F. Provide a full size equipment-grounding conductor in accordance with NEC included with

the power feeder. Terminate to the incoming power circuit-grounding terminal.




17710 - 25

G. All holes for field conduits, etc. shall be cut in the field, there shall be no additional holes,

factory cut holes, or hole closers allowed. Incorrect holes, additional holes, or miss-cut

holes shall require that the entire enclosure be replaced.

H. Control panels that are adjacent to motor control centers shall be fully wired to the motor

control centers using wireways integral to the motor control center or additional conduits

as needed. These interconnections are not shown or reflected on the conduit schedule,

but shall be shown on the Loop Drawings prepared by the Contractor.

I. Provide individually fused analog input module points with blown fuse indicator lights,

mounted external of the module on the output terminal strip:



3.04 CLEANING


3.05 PROTECTION


END OF SECTION

Durham AWWTF – FOG Tank Retrofit Project Schedules: I/O List



17903 - 1

SECTION 17903

SCHEDULES: I/O LIST

GENERAL

1.01 SUMMARY

A. The I/O list is not a take-off list. Additional information is as indicated on the Drawings and

specified in the Contract Documents. Where any discrepancies between this list and the P&ID

drawings arise, the P&ID shall govern.

B. Abbreviations used in the I/O list are defined on the Drawings.

PRODUCTS

A. Not used.

EXECUTION

3.01 I/O LIST

A. I/O list attached.

B. Use the descriptions on the I/O list for development of shop drawings.

END OF SECTION

SECTION 17903

I/O LIST

Equipment Tag I/O Tag PLC/SCADA Suffix Description Type Sheet PLC Rack Slot Point PLC Address Field Device

FI 715FIT6402 AI I010 7 22 3 6 WX1311 FLOW TRANSMITTER

FI 715FIT6404 AI I010 7 22 3 7 WX1312 FLOW TRANSMITTER

715FV6409 YI 460FCV1909 IN REMOTE DI I109 16 ELECTRIC ACTUATOR

715FV6409 ZIC GATE ACTUATOR CLOSED DI I109 16 ELECTRIC ACTUATOR

715FV6409 ZIO GATE ACTUATOR OPEN DI I109 16 ELECTRIC ACTUATOR

715FV6409 ZSC GATE ACTUATOR CLOSE COMMAND DO I109 16 ELECTRIC ACTUATOR

715FV6409 ZSO GATE ACTUATOR OPEN COMMAND DO I109 16 ELECTRIC ACTUATOR











YI TEMP TANK 3 MIXER 1 RUNNING DI I011 16 3 6 0 TANK 3 CONTROL PANEL

YA TEMP TANK 3 MIXER 1 OVERLOAD DI I011 16 3 6 1 TANK 3 CONTROL PANEL















END OF SECTION

Forest Grove WWTF – Clarifier Project



I/O List

17903 -1

CLEAN WATER SERVICES...ANSI B74.18 Grading of CertainAbrasive Grain on CoatedAbrasive MaterialASTM...

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