HomeMy WebLinkAboutC2024-086 - 4/16/2024 - Approved
CONTRACT DOCUMENTS
FOR CONSTRUCTION OF
Broadway Wastewater Treatment
Plant Rehabilitation
18084A
Plummer Associates, Inc
1320 South University Drive, Suite 300/Fort Worth, Texas
817-806-1700
TBPE Firm No. 13
Bid Set
July 2023
Record Drawing Number
STL-230
00 01 00 TABLE OF CONTENTS
Division /
Title
Section
Division 00 Contracting Requirements
00 01 00 Table of Contents
00 01 01 Seals Page
00 01 02 List of Drawings
00 52 23 Agreement (Rev 12-2021)
00 72 00 General Conditions (Rev 6-2021)
00 73 00 Supplementary Conditions (Rev 4-2022)
Division 01 General Requirements
01 11 00 Summary of Work (Rev 10-2018)
01 23 10 Alternates and Allowances (Rev 5-2020)
01 29 01 Measurement and Basis for Payment (Rev 5-2020)
01 33 01 Submittal Register (Rev 10-2018)
01 35 00 Special Procedures (Rev 10-2018)
01 50 00 Temporary Facilities and Controls (Rev 8-2019)
01 57 00 Temporary Controls (Rev 8-2019)
Part S Standard Specifications
025424 Hot Mix Asphaltic Pavement
028020 Seeding
028040 Sodding
Part T Technical Specifications
01 12 16 Sequence of Construction
01 32 33 Photographic Documentation
01 33 00 Submittal Procedures
(1)
01 35 73 Delegated Design Procedures
01 40 00 Quality Requirements
01 42 00 References
01 43 33 Manufacturer’s Field Services
01 60 00 Product Requirements
01 70 00 Execution Requirements
(1)
01 71 23 Field Engineering
01 73 29 Cutting and Patching
Table of Contents 00 01 00 - 1
Broadway Wastewater Treatment Plant Rehabilitation, Project #18084A Rev 1/2022
Division /
Title
Section
01 75 25 Equipment Testing and Startup
01 77 00 Closeout Procedures
01 78 23 Operation and Maintenance Data
01 78 36 Warranties
01 78 39 Project Record Documents
01 79 00 Demonstration and Training
02 41 00 Demolition
02 41 19 Selective Demolition
(1)
03 00 05 Concrete
(1)
03 15 19 Anchorage to Concrete
03 64 01 Injection Grouting - Hydrophilic
05 05 23 Metal Fastenings and Anchor Bolts
(1)
05 12 00 Structural Steel
06 64 00 FRP Grating, Handrails, and Structural Fabrications
(1)
07 92 00 Joint Sealants
09 91 00 Painting and Protective Coatings
(1)
09 97 13.26 Coating of Micropile Casings
10 14 19 Safety Signs
10 90 00 Identification, Stenciling, and Tagging
(2)
26 00 00 Electrical General Provisions
(2)
26 05 05 Selective Demolition for Electrical
(2)
26 05 19 Low-Voltage Electrical Power Conductors and Cables
(2)
26 05 26 Grounding and Bonding for Electrical Systems
(2)
26 05 29 Hangers and Supports for Electrical Systems
(2)
26 05 33 Raceways and Boxes for Electrical Systems
(2)
26 05 36 Cable Trays for Electrical Systems
(2)
26 05 43 Underground Ducts and Raceways for Electrical Systems
(2)
26 05 53 Identification for Electrical Systems
(2)
26 27 00.11 Mini-Power Centers
(2)
26 27 26 Wiring Devices
(2)
26 27 29 Switch Rated Plugs and Receptacles
(2)
26 28 16 Enclosed Switches and Circuit Breakers
(2)
26 29 03 Low-Voltage Pilot Control Devices
(2)
26 41 00 Facility Lightning Protection
(2)
27 15 23 Fiber Optic Equipment
31 10 00 Site Clearing
Table of Contents 00 01 00 - 2
Broadway Wastewater Treatment Plant Rehabilitation, Project #18084A Rev 1/2022
Division /
Title
Section
31 20 00 Earthwork
31 23 00 Excavation, Trenching, and Backfilling for Utilities
31 23 16 Excavation Support and Protection
31 23 19 Dewatering
31 50 00 Maintenance of Excavation Support and Protection
(1)
31 62 18 Micropiles
(1)
31 63 29 Drilled Piers
31 70 00 Pipe Jacking, Boring, and Tunneling
32 11 34 Cement Stabilized Sand
32 12 73 Paving Joints Sealants
33 05 61 Manholes
33 14 19 Drains, Cleanouts, Hydrants, and Hose Stations
40 01 05 Field Testing of Piping Systems
40 05 05 Piping System, Basic Materials and Methods
40 05 07 Hangers and Supports for Piping Systems
40 05 19 Ductile Iron Pipe
40 05 23 Stainless Steel Process Pipe and Tubing
40 05 24 Steel Pipe
40 05 31.13 Polyvinyl Chloride and Chlorinated Polyvinyl Chloride Process Pipe
(4)
40 05 36.13 Foul Air Fiberglass Ductwork
40 05 51 Common Requirements for Process Valves
40 05 52 Miscellaneous Valves and Appurtenances
40 05 57.23 Electric Motor Actuators
40 05 62 Plug Valves
40 05 64 Butterfly Valves
(4)
40 05 64.43 Fiberglass Dampers
40 05 91 Common Control Panel Requirements for Process Equipment
(2)
40 05 93 Common Motor Requirements for Process Equipment
40 41 13 Process Piping Heat Tracing
40 42 13 Process Piping Insulation
40 46 16 Protective Liquid Linings and Coatings for Substrates Exposed to a Corrosive
Wastewater Environment
(3)
40 61 00 Process Control and Instrumentation Systems – General Provisions
(3)
40 61 21 Process Control System – Testing
(3)
40 61 21A Process Control System – Testing Forms
(3)
40 61 26 Process Control System – Training
Table of Contents 00 01 00 - 3
Broadway Wastewater Treatment Plant Rehabilitation, Project #18084A Rev 1/2022
Division /
Title
Section
(3)
40 61 93 Process Control System – Input/Output List
(3)
40 61 93A Process Control System – Input/Output List Attachment
(3)
40 61 96 Process Control Descriptions
(3)
40 61 96A Process Control Descriptions – Att. A – Aeration Blowers and Aeration Basins
(3)
40 61 96B Process Control Descriptions – Att. B – Resaca Lift Station
(3)
40 63 00 PLC Hardware and Software
(3)
40 63 00A Attachment A – PLC Hardware Schedule
(3)
40 66 00 Process Control System – Network Equipment
(3)
40 67 00 Process Control System – Control Panels and Components
(3)
40 68 00 Applications Engineering Services
(3)
40 68 00A Applications Engineering Services – Att. A – Existing HMI Screens
(3)
40 70 00 Process Control System – Instruments
(3)
40 70 00A Attachment A – Instrument Schedule
40 73 99 Piping System, Pressure Gauges and Thermometers
43 11 19 Foul Air Fans
43 21 39 Pump, Dry Pit Submersible – Centrifugal
43 22 10 Common Requirements for Pumps
(4)
44 31 11 Biological Tower Type Odor Control System
(4)
44 31 16 Carbon Adsorber Odor Control System
(4)
44 31 83 Foul Air Collection System Testing, Adjusting, and Balancing
46 21 83 Septage Receiving Station
46 23 63 Grit Classifying and Washing Equipment
46 43 21 Circular Clarifier Equipment
Appendix 1 Geotechnical Report
Specification sections listed on this page were prepared by Jeffrey E. Caffey, Texas P.E. 81896 except
where noted:
(1)(3)
Arthur B. Colwell, Texas P.E. 60292 Sahar Saffarshamshirgar, Texas P.E. 125740
(2)(4)
Patrick N. Moseley, Texas P.E. 72794 Lynsy D. Nagle, Texas P.E. 113139
END OF SECTION
Table of Contents 00 01 00 - 4
Broadway Wastewater Treatment Plant Rehabilitation, Project #18084A Rev 1/2022
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00 52 23 AGREEMENT
This Agreement, for the Project awarded on April 16, 2024, is between the City of Corpus Christi (Owner)
and
Associated Construction Partners, Ltd. (Contractor).
Owner and Contractor agree as follows:
ARTICLE 1 – WORK
1.01 Contractor shall complete all Work as specified or indicated in the Contract Documents. The Work
is generally described as:
Project Name: Broadway WWTP Rehabilitation
Project Number: 18084A
ARTICLE 2 – DESIGNER AND OWNER’S AUTHORIZED REPRESENTATIVE
2.01 The Project has been designed by:
Plummer Associates, Inc.
1320 S. University Drive, Suite 300
Fort Worth, Texas, 76107
Contact: Jeff Caffey (jcaffey@plummer.com)
2.02 The Owner’s Authorized Representative for this Project is:
Joseph Johnson
City of Corpus Christi - Engineering Services
4917 Holly Road, Bldg. No. 5
Corpus Christi, TX 78411
Josephj2@cctexas.com
361-826-3691
ARTICLE 3 – CONTRACT TIMES
3.01 Contract Times
A. The Work is required to be substantially completed within 480 days after the date when the
Contract Times commence to run as provided in the Notice to Proceed and is to be completed
and ready for final payment in accordance with Paragraph 17.16 of the General Conditions
within 510 days after the date when the Contract Times commence to run.
B. Performance of the Work is required as shown in Paragraph 7.02 of the General Conditions.
Agreement 00 52 23 - 1
Broadway WWTP Rehabilitation 18084A Rev 12/2021
C. Milestones, and the dates for completion of each, are as defined in Section 01 35 00 SPECIAL
PROCEDURES.
3.02 Liquidated Damages
A. Owner and Contractor recognize that time limits for specified Milestones, Substantial
Completion, and completion and readiness for Final Payment as stated in the Contract
Documents are of the essence of the Contract. Owner and Contractor recognize that the
Owner will suffer financial loss if the Work is not completed within the times specified in
Paragraph 3.01 and as adjusted in accordance with Paragraph 11.05 of the General
Conditions. Owner and Contractor also recognize the delays, expense, and difficulties
involved in proving in a legal or arbitration proceeding the actual loss suffered by Owner if
the Work is not completed on time. Accordingly, instead of requiring any such proof, Owner
and Contractor agree that as liquidated damages for delay (but not as a penalty):
1. Substantial Completion: Contractor shall pay Owner $990.00 for each day that expires
after the time specified in Paragraph 3.01 for Substantial Completion until the Work is
substantially complete.
2. Completion of the Remaining Work: Contractor agrees to pay Owner $990.00 for each
day that expires after the time specified in Paragraph 3.01 for completion and readiness
for final payment until the Work is completed and ready for final payment in accordance
with Paragraph 17.16 of the General Conditions.
3. Liquidated damages for failing to timely attain Substantial Completion and Final
Completion are not additive and will not be imposed concurrently.
4. Milestones: Contractor agrees to pay Owner liquidated damages as stipulated in
SECTION 01 35 00 SPECIAL PROCEDURES for failure to meet Milestone completions.
5. The Owner will determine whether the Work has been completed within the Contract
Times.
B. Owner is not required to only assess liquidated damages, and Owner may elect to pursue its
actual damages resulting from the failure of Contractor to complete the Work in accordance
with the requirements of the Contract Documents.
ARTICLE 4 – CONTRACT PRICE
4.01 Owner will pay Contractor for completion of the Work in accordance with the Contract
Documents at the unit prices shown in the attached BID FORM. Unit prices have been computed
in accordance with Paragraph 15.03 of the General Conditions. Contractor acknowledges that
estimated quantities are not guaranteed, and were solely for the purpose of comparing Bids, and
final payment for all unit price items will be based on actual quantities, determined as provided
in the Contract Documents.
Total Base Bid + Alt 1 Price $ 13,484,305.00
ARTICLE 5 – PAYMENT PROCEDURES
5.01 Submit Applications for Payment in accordance with Article 17 of the General Conditions.
Applications for Payment will be processed by the OAR as provided in the General Conditions.
Agreement 00 52 23 - 2
Broadway WWTP Rehabilitation 18084A Rev 12/2021
5.02 Progress Payments; Retainage:
A. The Owner will make progress payments on or about the 25th day of each month during
performance of the Work. Payment is based on Work completed in accordance with the
Schedule of Values established as provided in the General Conditions.
B. Progress payments equal to the full amount of the total earned value to date for completed
Work minus the retainage listed below and properly stored materials will be made prior to
Substantial Completion.
1. The standard retainage is 5 percent.
C. Payment will be made for the amount determined per Paragraph 5.02.B, less the total of
payments previously made and less set-offs determined in accordance with Paragraph 17.01
of the General Conditions.
D. At the Owner’s option, Owner may pay Contractor 100 percent of the Work completed, less
amounts withheld in accordance with Paragraph 17.01 of the General Conditions and less
200 percent of OAR’s estimate of the value of Work to be completed or corrected to reach
Substantial Completion. Owner may, at its sole discretion, elect to hold retainage in the
amounts set forth above for progress payments prior to Substantial Completion if Owner has
concerns with the ability of the Contractor to complete the remaining Work in accordance
with the Contract Documents or within the time frame established by this Agreement.
Release or reduction in retainage is contingent upon and consent of surety to the reduction
in retainage.
5.03 Owner will pay the remainder of the Contract Price as recommended by OAR in accordance with
Paragraph 17.16 of the General Conditions upon Final Completion and acceptance of the Work.
ARTICLE 6 – INTEREST ON OVERDUE PAYMENTS AND RETAINAGE
6.01 The Owner is not obligated to pay interest on overdue payments except as required by Texas
Government Code Chapter 2251. Invoices must comply with Article 17 of the General Conditions.
6.02 Except as specified in Article 5, the Owner is not obligated to pay interest on moneys not paid
except as provided in Texas Government Code Chapter 2252.
ARTICLE 7 – CONTRACTOR’S REPRESENTATIONS
7.01 The Contractor makes the following representations:
A. The Contractor has examined and carefully studied the Contract Documents and the other
related data identified in the Bidding Documents.
B. The Contractor has visited the Site and become familiar with and is satisfied as to the general,
local, and Site conditions that may affect cost, progress, and performance of the Work.
C. The Contractor is familiar with Laws and Regulations that may affect cost, progress, and
performance of the Work.
D. The Contractor has carefully studied the following Site-related reports and drawings as
identified in the Supplementary Conditions:
1. Geotechnical Data Reports regarding subsurface conditions at or adjacent to the Site;
Agreement 00 52 23 - 3
Broadway WWTP Rehabilitation 18084A Rev 12/2021
2. Drawings of physical conditions relating to existing surface or subsurface structures at
the Site;
3. Underground Facilities referenced in reports and drawings;
4. Reports and drawings relating to Hazardous Environmental Conditions, if any, at or
adjacent to the Site; and
5. Technical Data related to each of these reports and drawings.
E. The Contractor has considered the:
1. Information known to Contractor;
2. Information commonly known to contractors doing business in the locality of the Site;
3. Information and observations obtained from visits to the Site; and
4. The Contract Documents.
F. The Contractor has considered the items identified in Paragraphs 7.01.D and 7.01.E with
respect to the effect of such information, observations, and documents on:
1. The cost, progress, and performance of the Work;
2. The means, methods, techniques, sequences, and procedures of construction to be
employed by Contractor; and
3. Contractor’s safety precautions and programs.
G. Based on the information and observations referred to in the preceding paragraphs,
Contractor agrees that no further examinations, investigations, explorations, tests, studies,
or data are necessary for the performance of the Work at the Contract Price, within the
Contract Times, and in accordance with the other terms and conditions of the Contract
Documents.
H. The Contractor is aware of the general nature of Work to be performed by Owner and others
at the Site that relates to the Work as indicated in the Contract Documents.
I. The Contractor has correlated the information known to the Contractor, information and
observations obtained from visits to the Site, reports and drawings identified in the Contract
Documents, and all additional examinations, investigations, explorations, tests, studies, and
data with the Contract Documents.
J. The Contractor has given the OAR written notice of all conflicts, errors, ambiguities, or
discrepancies that the Contractor has discovered in the Contract Documents, and the written
resolution provided by the OAR is acceptable to the Contractor.
K. The Contract Documents are generally sufficient to indicate and convey understanding of all
terms and conditions for performance and furnishing of the Work.
L. Contractor’s entry into this Contract constitutes an incontrovertible representation by
Contractor that without exception all prices in the Agreement are premised upon performing
and furnishing the Work required by the Contract Documents.
M. CONTRACTOR SHALL INDEMNIFY, DEFEND AND HOLD HARMLESS THE OWNER’S
INDEMNITEES IN ACCORDANCE WITH PARAGRAPH 7.14 OF THE GENERAL CONDITIONS
AND THE SUPPLEMENTARY CONDITIONS.
Agreement 00 52 23 - 4
Broadway WWTP Rehabilitation 18084A Rev 12/2021
ARTICLE 8 – ACCOUNTING RECORDS
8.01 Accounting Record Availability: The Contractor shall keep such full and detailed accounts of
materials incorporated and labor and equipment utilized for the Work consistent with the
requirements of Paragraph 15.01 of the General Conditions and as may be necessary for proper
financial management under this Agreement. Subject to prior written notice, the Owner shall be
afforded reasonable access during normal business hours to all of the Contractor’s records, books,
correspondence, instructions, drawings, receipts, vouchers, memoranda, and similar data relating
to the Cost of the Work and the Contractor’s fee. The Contractor shall preserve all such
documents for a period of 3 years after the final payment by the Owner.
ARTICLE 9 – CONTRACT DOCUMENTS
9.01 Contents:
A. The Contract Documents consist of the following:
1. Solicitation documents.
2. Specifications, forms, and documents listed in SECTION 00 01 00 TABLE OF CONTENTS.
3. Drawings listed in the Sheet Index.
4. Addenda.
5. Exhibits to this Agreement:
a. Contractor’s Bid Form.
b. Wastewater Consent Decree
6. Documentation required by the Contract Documents and submitted by Contractor prior
to Notice of Award.
B. There are no Contract Documents other than those listed above in this Article.
C. The Contract Documents may only be amended, modified, or supplemented as provided in
Article 11 of the General Conditions.
Agreement 00 52 23 - 5
Broadway WWTP Rehabilitation 18084A Rev 12/2021
ARTICLE 10 – CONTRACT DOCUMENT SIGNATURES
ATTEST CITY OF CORPUS CHRISTI
Rebecca Huerta Jeffrey Edmonds, P.E
City Secretary Director of Engineering Services
__________________________ AUTHORIZED
APPROVED AS TO LEGAL FORM: BY COUNCIL ___________________________
Assistant City Attorney
ATTEST (IF CORPORATION) CONTRACTOR
Associated Construction Partners, Ltd
(Seal Below) By:
Title:
Note: Attach copy of authorization to sign if
person signing for CONTRACTOR is not President,
Vice President, Chief Executive Officer, or Chief
215 W. Bandera Rd., Suite 114-461
Financial Officer
Address
Boerne, TX 78006
City State Zip
(210) 698-8714
Phone Fax
jill@acpartners.org
EMail
Agreement 00 52 23 - 6
Broadway WWTP Rehabilitation 18084A Rev 12/2021
WASTEWATER CONSENT DECREE
Special Conditions
Special Project procedures are required from the CONTRACTOR as specified herein. The CONTRACTOR
shall implement and maintain these procedures at the appropriate time, prior to and during
performance of the work.
The following special conditions and requirements shall apply to the Project:
I. Consent Decree Notice Provision – The City of Corpus Christi (“City”), the United States of
America and the State of Texas have entered into a Consent Decree in Civil Action No. 2:20-cv-00235,
United States of America and State of Texas v. City of Corpus Christi in the United States District Court for
the Southern District of Texas, Corpus Christi Division (the “Consent Decree”). A copy of the
Consent Decree is available at
https://www-cdn.cctexas.com/sites/default/files/CC-Consent-Decree.pdf
By signature of the Contract, CONTRACTOR acknowledges receipt of the Consent Decree.
II. Performance of work. CONTRACTOR agrees that any work under this Contract is conditioned upon
CONTRACTOR’s performance of the Work in conformity with the terms of the Consent Decree. All
Work shall be performed in accordance with the Design Criteria for Wastewater Systems under Title 30
Chapter 217 of the Texas Administrative Code, 30 Tex. Admin. Code Ch. 217, and using sound engineering
practices to ensure that construction, management, operation and maintenance of the Sewer
Collection System complies with the Clean Water Act. Work performed pursuant to this contract is
work that the City is required to perform pursuant to the terms of the Consent Decree. In the event
of any conflict between the terms and provisions of this Consent Decree and any other terms and
provisions of this Contract or the Contract Documents, the terms and provisions of this Consent Decree
shall prevail.
III. Retention of documents – CONTRACTOR shall retain and preserve all non- identical copies of
all documents, reports, research, analytical or other data, records or other information of any kind or
character (including documents, records, or other information in electronic form) in its or its sub-
contractors’ or agents’ possession or control, or that come into its or its sub-contractors’ or
agents’ possession or control, and that relate in any manner to this contract, or the performance of any
work described in this contract (the “Information”). This retention requirement shall apply regardless
of any contrary city, corporate or institutional policy or procedure. CONTRACTOR, CONTRACTOR’s
Agreement 00 52 23 - 7
Broadway WWTP Rehabilitation 18084A Rev 12/2021
sub-contractors and agents shall retain and shall not destroy any of the Information until five years after
the termination of the Consent Decree and with prior written authorization from the City Attorney.
CONTRACTOR shall provide the City with copies of any documents, reports, analytical data, or other
information required to be maintained at any time upon request from the City.
IV. Liability for stipulated penalties – Article IX of the Consent Decree provides that the United
States of America, the United States Environmental Protection Agency and the State of Texas may
assess stipulated penalties including interest against the City upon the occurrence of certain events. To
the extent that CONTRACTOR or CONTRACTOR’s agents or sub-contractors cause or contribute to, in
whole or in part, the assessment of any stipulated penalty against the City, CONTRACTOR agrees that it shall
pay to City the full amount of any stipulated penalty assessed against and paid by City that is caused or
contributed to in whole or in part by any action, failure to act, or failure to act within the time required
by any provision of this contract. CONTRACTOR shall also pay to City all costs, attorney fees, expert
witness fees and all other fees and expenses incurred by City in connection with the assessment or
payment of any such stipulated penalties, or in contesting the assessment or payment of any such
stipulated penalties. In addition to any and all other remedies to which City may be entitled at law
or in equity, CONTRACTOR expressly authorizes City to withhold all amounts assessed and paid as
stipulated penalties, and all associated costs, fees, or expenses from any amount unpaid to
CONTRACTOR under the terms of this contract, or from any retainage provided in the contract.
END OF SECTION
Agreement 00 52 23 - 8
Broadway WWTP Rehabilitation 18084A Rev 12/2021
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Associated Construction Partners, Ltd.
Jill Simpson
President
Rachel Fitchett
Texas
26-2197773
215 W Bandera Rd., Ste. 114-461
Boerne, TX 78006
210-698-8714 jill@acpartners.org
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01 23 10ALTERNATES AND ALLOWANCES
GENERAL
1.1REQUIREMENTS
Alternates:
This Section describes each alternate by number and describes the basic changes to
be incorporated into the Work when this alternate is made a part of the Work in the
Agreement.
Drawings and Specifications will outline the extent of Work to be included in the
alternate Contract Price.
Coordinate related Work and modify surrounding Work as required to properly
integrate the Work under each alternate, and provide a complete and functional
Project as required by the Contract Documents.
Bids for alternates may be accepted or rejected at the option of the Owner.
Owner may incorporate these alternates in the Contract when executed, or may
issue a Change Order to incorporate these alternates within 120 days at the prices
offered in the Bid, unless noted otherwise. A Request for a Change Proposal may be
issued after 120 days or other designated time period to negotiate a new price for
incorporating the Work into the Project.
Allowances:
Include specified allowance amount in the Contract Price.
The amount of each allowance includes:
The cost of the product to the Contractor less any applicable trade discounts.
Delivery to the Site.
Applicable taxes.
Include in the Contract Price all costs for:
Handling at the Site, including unloading, uncrating, and storage perArticle 19
of SECTION 007200GENERAL CONDITIONS.
Cost for labor and equipment for installation and finishing.
Cost for related products not specifically listed in the allowance required for
installation, including consumable supplies and materials.
All overhead, profit, and related costs.
Assist Owner in the selection of products.
Identify qualified Suppliers.
Obtain bidsfrom qualified Suppliers.
Present available alternates to the Owner through the OAR. Notify OARof:
Any objections to a particular Supplier or product.
Effect on the Construction Schedule anticipated by the selection of each
option.
Cost of each option.
Upon selection of the product:
Purchase and install the product.
Contractor’s responsibilities for products shall be the same as for products
selected by the Contractor.
Alternates and Allowances01 23 10 -1
Broadway Wastewater Treatment Plant RehabilitationRev 5/2020
18084A
Submit a Change Proposal per Article 12 of SECTION 00 72 00 GENERAL CONDITIONS
to adjust Contract Price if the net cost of the product is more or less than the
specified amount.
Adjust the unit cost applied to the quantities installed per the method of
payment described in Article 17 of SECTION 00 72 00 GENERAL CONDITIONS
for products specified as Unit Price Work.
Do not perform Work until selection of alternate has been approved by the
Owner.
Provide actual invoices for the materials.
The Bid Items described as “Allowances” have been set as noted in Section 00 30 00 BID
FORMand shall be included in the Total Base Bid of the Bid Form for each Bidder. These
Allowances may be used at the Owner’s discretion in the event that unforeseen conditions
or conflicts are encountered during construction that warrants the use of the Allowance
funds. Ifthe use of Allowance funds becomesnecessary, the OAR will provide written
authorization at a cost negotiated between Owner and Contractor, using unit prices in the
Bid Form when applicable. No work is to be performed under the Allowance items without
written authorization from the OAR. There is no guarantee that any of these funds will
need to be used during the course of the Work.The following Allowances have been
provided for this project:
1.2DOCUMENT SUBMITTALS
Provide documentsfor materials furnished as part of the alternate in accordance with
Article 24 of SECTION 00 72 00 GENERAL CONDITIONS.
1.3DESCRIPTION OF ALTERNATES
Additive Alternates
Additive Alternate I1–Secondary ClarifiersNo. 1and No. 2Rehabilitation.
Additive Alternate I1a:Secondary Clarifier No. 1and No. 2 Equipment
Payment shall include construction of all work required to replace
existing Secondary ClarifiersNo. 1and No. 2equipment with new clarifier
equipment as shown in the 24-Series drawings, contract documents and
specifications, complete in place, and placed in operation (except for Bid
Item as listed separately below) for a lump sum amount.
Measurement for payment will be made per the Schedule of Values
based on the amount of work that has been performed.
Additive Alternate I1b: Secondary Clarifier No. 1 and No. 2 Electrical and
Instrumentation
Payment shall include all work to furnish and install the electrical and
instrumentation equipment and appurtenances for the Secondary
ClarifiersNo.1and No. 2, complete in place, as shown in the 24-Series
Drawings and described in the contract documents, per Lump Sum.
Measurement for payment will be made per the Schedule of Values
based on the amount of work that has been performed.
Alternates and Allowances01 23 10 -2
Broadway Wastewater Treatment Plant RehabilitationRev 5/2020
18084A
1.4DESCRIPTION OF ALLOWANCES
Allowance A-2(Bid Item A-2)–Bonds and Insurance
A maximum of 2% of the bid price to be used for the purchase of bonds and
insurance required for the Project.
Allowance A-3(Bid Item A-3) -Allowance for Fine-Bubble Diffuser System Repair:
The sum of $50,000 to be used for the purchase of fine-bubble diffuser system repair
material. Payment shall include any unanticipated work encountered during the
work. Payment shall only be made after written authorization to complete the
unanticipated work. Payment for all other unanticipated work shall be made under
Bid Item A-5.
The Bid Item A-3 shall be included in the Total Base Bid for each Bidder. This
allocation may be used at the OAR’s discretion should fine-bubble diffuser system
repair be required during construction and warrant the use of the allocated funds,
except for the unanticipated conditions described in Bid Item A-5. Should the use of
funds from Bid Item A-3 become necessary, the OAR will provide written
authorization at a cost negotiated between the City and the Contractor. Payment
shall be negotiated for each circumstance. There is no guarantee that any of these
funds will need to be used throughout the course of the work. Any unused funds in
Bid Item A-3 shall be returned to the Owner as a credit after completion of the work.
Allowance A-4(Bid Item A-4) –Allowance for Additional Concrete Basin Wall Leak Repair
The sum of $100,000to be used for the purchase of additional concrete basin wall
leak repair.
Bid Item C-6Bid Items B-4 and B-5,as described in SECTION 01 29 00 MEASUREMENT
AND BASIS FOR PAYMENT providesfor concrete basin wall leak repair per SECTION
5
07 92 00 HYDROPHILLIC INJECTION GROUTING for a set amount of crack length. Bid
ItemA-4provides an allowance for additional concrete basin wall leak repair when
the amount in Bid Items C-6Bid Items B-4 and B-5isspent. The additional work will
be based on the unit price in Bid Item C-6Bid Items B-4 and B-5. Priority of leaks to
be addressed will be determinedby Owner. Payment shall only be made after
written authorization to complete the work.
The Bid Item A-4 shall be included in the Total Base Bid for each Bidder. This
allocation may be used at the OAR’s discretion should an unanticipated condition
warrant the use of the allocated funds while completing work on the Aeration Basin
structural repairs. Should the use of funds from Bid Item A-4 become necessary, the
OAR will provide written authorization at a cost negotiated between the City and the
Contractor. Payment shall be negotiated for each circumstance. There is no
guarantee that any of these funds will need to be used throughout the course of the
work. Any unused funds in Bid Item A-4 shall be returned to the Owner as a credit
after completion of the work.
Allowance A-5 (BidItem A-5)–Allowance for Unforeseen Items
The sum of $800,000 to be used for the purchase of unforeseen items.
Payment shall include any unforeseen items encountered during the work. Payment
shall only be made after written authorization to complete the unanticipated work.
Alternates and Allowances01 23 10 -3
Broadway Wastewater Treatment Plant RehabilitationRev 5/2020
18084A
The Allowance Bid Item A-5 shall be included in the Total Base Bid for each Bidder.
This allocation may be used at the OAR’s discretion should an unanticipated
condition warrant the use of the allocated funds, except for the unanticipated
conditions described in Bid Item A-3 or A-4. Should the use of funds from Bid Item A5
become necessary, the OAR will provide written authorization at a cost negotiated
between the City and the Contractor. Payment shall be negotiated for each
circumstance. There is no guarantee that any of these funds will need to be used
throughout the course of the work. Any unused funds in Bid Item A-5 shall be
returned to the Owner as a credit after completion of the work.
Allowance A-6 (Bid Item A-6)–Allowance for Permits
The sum of $20,000 to be used for the purchase of permits.
Payment shall include all permits required to construct the Project.
Contractor shall provide documentation of all permits and will be reimbursed
for the cost. Documentation shall include receipts and other items the Owner
deems necessary.
PRODUCTS (NOT USED)
EXECUTION (NOT USED)
END OF SECTION
Alternates and Allowances01 23 10 -4
Broadway Wastewater Treatment Plant RehabilitationRev 5/2020
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01 29 01MEASUREMENT AND BASIS FOR PAYMENT
GENERAL
1.1MEASUREMENT AND BASIS FOR PAYMENTS ON LUMP SUM ITEMS
Include all cost for completing the Work in accordance with the Contract Documents for
lump sum payment items. Include all direct cost for the Work associated with that lump
sum item and a proportionate amount for the indirect costs as described in Article 17 of
SECTION 00 72 00 GENERAL CONDITIONSfor each lump sum item. Include cost not
specifically set forth as an individual payment item but required to provide a complete and
functional system in the lump sum price.
Measurement for progress payments will be made on the basis of the earned value for
each item shown as a percentage of the cost for the lump sum item as described in Article
17 of SECTION 00 72 00 GENERAL CONDITIONS. Payment at Final Completion will be equal
to the total lump sum amount for that item.
1.2MEASUREMENT AND BASIS FOR PAYMENTS ON UNIT PRICE ITEMS
Include all cost for completing the Work in accordance with the Contract Documents in unit
price payment items. Include all direct costsfor the Work associated with that unit price
item and a proportionate amount for the indirect costs as described in Article 17 of
SECTION 00 72 00 GENERAL CONDITIONSfor each unit price item. Include costsnot
specifically set forth as an individual payment item but required to provide a complete and
functional system in the unit price.
Measurement for payments will be made only for the actual measured and/or computed
length, area, volume, solid contents, number,and weight, unless other provisions are made
in the Contract Documents. Payment on a unit price basis will not be made for Work
outside finished dimensions shown in the Contract Documents. Include cost for waste,
overages,and tolerances in the unit price for that line item. Measurement will be as
indicated for each unit price item.
1.3MEASUREMENT AND BASIS FOR PAYMENT FOR BASE BIDITEMS
General
BidItem A1 –Mobilization(Maximum 5%):
Include the following costs in this Biditem:
Transportation and setup for equipment;
Transportation and/or erection of all field offices, sheds,temporary, and
storage facilities;
Salaries for preparation of documentsrequired before the first Application
for Payment;
Salaries for field personnel assigned to the Project related to the
mobilization of the Project;
Demobilization; and
Mobilization may not exceed 5 percent of the total Contract Price.
Measurementfor payment will be made per lump sum on the following basis:
When at least 5% of the adjusted contract amount for construction is earned,
75% of the mobilization lump sum bid amount will be eligible for payment,
minus retainage. Upon substantialcompletion of all work under this Contract
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and removal of all equipment and materials from the Project site, the remaining
25% of the mobilization lump sum bid amount will be eligible for payment,
minus retainage.
Bid Item A2 –Bonds and Insurance(Maximum Allowance of 2%)
Payment shall include all bonds and insurance required under the Contract
Documents.
Measurement for payment for bonds and insurance will be based on the receipt
of documentation of actual costs. Contractor shall furnish satisfactory evidence
of the rate or rates paid for all bonds and insurance. Contractor will be
reimbursed for the actual cost of unique insurance as required and obtained
specifically for this Project, not including the routine and general company
insurance policies that are maintained for the course of conducting normal
business operations. Contractor will be reimbursed for the actual cost of
project specific bonds and insurance, not to exceed the bid amount or the
verifiable costs of Project specific bonds and insurance incurred by the
Contractor.
Bid Item A3: Refer to SECTION 01 23 10 ALTERNATES AND ALLOWANCES.
Bid Item A4: Refer to SECTION 01 23 10 ALTERNATES AND ALLOWANCES.
Bid Item A5: Refer to SECTION 01 23 10 ALTERNATES AND ALLOWANCES.
Bid Item A6: Refer to SECTION 01 23 10 ALTERNATES AND ALLOWANCES.
Bid Item A7–Extra Work: Additional 24-inch Concrete Pier Depth
Measurement for payment will be made per vertical linear foot on the following
basis:Contractor shall furnish satisfactory evidence of the additional vertical
linear footage of concrete pier depth needed to complete the Project.
Payment will be made based on the actual cost of the additional vertical linear
footageneeded.
Bid Item A8–Extra Work: 14-inch2205 Duplex Stainless Steel Pipe, Furnished and
Installed
Measurement for payment will be made per linear foot on the following basis:
Contractor shall furnish satisfactory evidence of the additional linear footage of
14-inch2205 duplex stainless steel pipe, couplings, appurtenances, and
supports,furnished and installed to complete the Project.
Payment will be made based on the actual cost of the additional linear footage
of pipe furnished and installed.
Bid Item A9–Extra Work: 10” 2205 Duplex Stainless Steel Pipe, Furnished and
Installed
Measurement for payment will be made per linear foot on the following basis:
Contractor shall furnish satisfactory evidence of the additional linear footage of
10-inch2205 duplex stainless steel pipe, couplings, appurtenances, and
supports,furnished and installed to complete the Project.
Payment will be made based on actual cost of the additional linear footage of
pipe furnished and installed.
Bid Item A10–Extra Work: 8” 2205 Duplex Stainless Steel Pipe, Furnished and
Installed
Measurement for payment will be made per linear foot on the following basis:
Contractor shall furnish satisfactory evidence of the additional linear footage of
8-inch2205 duplex stainless steel pipe, couplings, appurtenances, and
supports,furnished and installed to complete the Project.
Payment will be made based on the actual cost of the additional linear footage
of pipe furnished and installed.
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Bid Item A11–Extra Work: Concrete Roadway (8-inch thickness) Repair, Furnished
and Installed
Measurement for payment will be made per square yardon the following basis:
Contractor shall furnish satisfactory evidence of the additional 8-inch concrete
roadway repair required for the Project.
Payment will be made based on the actual cost of additional square yards of
concrete roadway way repair, furnished and installed.
Broadway Wastewater Treatment Plant Rehab:
Bid Item B1 –Construction of all Work Except for Bid Items Listed Separately
Payment shall include construction of all work for the Broadway WWTP
Rehabilitation project, complete and placed in operation, as shown on the plans
and described in the specifications, except for items described in other Bid
Items. The quantities listed for the separate bid items described below are
estimates. Any additional quantities required to complete the work as shown
on the Drawings are included in this lump sum amount.
Measurement for payment will be made perthe Schedule of Values based on
the amount of the work that has been performed.
Bid Item B2–Broadway WWTP Electrical and Instrumentation
Payment shall include construction of all electrical and instrumentation workfor
the Broadway WWTP Rehabilitation project, complete and placed in operation,
as shown on the plans and described in the specifications, except for items
described in other Bid Items. The quantities listed for the separate bid items
described below are estimates. Any additional quantities required to complete
the work as shown on the Drawings are included in this lump sum amount.
Measurement for payment will be made perthe Schedule of Values based on
the amount of the work that has been performed.
Bid Item B3 –Concrete Testing
Payment shall include all work required to conduct concrete testing for the
Projectas described in the drawings and specifications, except for items that
are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Refer to Specification Section 03 00 05 Concrete and Specification Section 31
63 29 Drilled Piers for concrete testing requirements.
5
Bid Item B4–Concrete Basin Wall Crack Repair, 2-foot-thick walls
Payment shall include all work required to furnish and install exterior wall
Hydrophilic Injection Grouting according toSECTION03 64 00in the Aeration
Basin Walls and the Headworks Structure that are 2-feet thick, except for items
that are described in the other Bid Items.
Measurement for payment will be made per linear footof surface crack length
of the work that has been performed.
Bid Item B5–Concrete Basin Wall Crack Repair, less than 2-foot-thickwalls and
suspended channel slabs
Payment shall include all work required to furnish and install concrete basin
wall crack repair per SECTION03 64 00HYDROPHILLIC INJECTION
GROUTING, in the Aeration Basin Walls and the Headworks Structure that are
less than 2-feet thick, complete in place, except for items that are described in
the other Bid Items.
Measurement for payment will be made per linear footof surface crack length
of the work that has been performed.
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Site Work and Yard Piping:
Bid Item C1 –Trench Safety System
Payment shall include all Work required to develop, design, implement, and
monitor excavation and support systems for underground utilities. Systems
shall be in accordance with Occupational Safety and Health Administration
guidelines.
Measurement for payment will be made per lump sum as a percentage of the
Work that has been performed.
Bid Item C2–Storm Water Pollution PreventionPlan
Payment shall include but not be limited to furnishing and submitting the
SWPPP to TCEQ and Owner and updating the Plan during the Project as
needed. All permits and required fees related to the SWPPP will be included in
this item.
Measurement for payment will be made per lump sum on the following basis:
The initial pay application will include 50% of the lump sum bid amount. The
balance will be paid according to the percent of construction completion after
50% completion has occurred.
Bid Item C3–Seeding and Sodding
Payment shall include all Work required for seeding and/or sodding where
required for the Project.
Measurement for payment will be made per lump sum as a percentage of the
Work that has been performed.
Bid Item C4 –Hot Mix AsphalticConcretePavement
Payment shall include all work required to furnish and install hot mix asphaltic
concrete pavement and subbaseat the Septage Receiving Station as shown in
the 05 Series drawings and described in the specifications, except for items
that are described in the other Bid Items.
Measurement for payment will be made per square yard of the work that has
been performed.
Bid Item C5–Aeration BasinDrainLine
Payment shall include all work required to furnish and install the 16-inchPVC
aeration basin drain line(6’-10’ Depth) including DIP fittings, couplings, and
appurtenances, excavation and backfill,complete and in place as shown in the
01-Series drawings and described in the specifications, except for items that
are described in the other Bid Items.
Measurement for payment will be made per linear foot of the workthat has
been performed.
Bid Item C6–Aeration Basin Drain Line 16-inch Plug Valves
Payment shall include all work required to furnish and install the16-inch plug
valvesand operators on the Aeration Basin Drain Line complete and in placeas
described in the specifications and shown in the 01-Series drawings, except for
items that are described in the other Bid Items.
Measurement for payment will be made per each installed plug valvethat has
been performed.
Bid Item C7–Aeration Basin Drain Line ValveVaults
Payment shall include all work required to furnish and install thevalve vaultson
the Aeration Basin Drain Line, complete and in placeas described in the
specifications and shown in the 01-Series drawings, except for items that are
described in the other Bid Items.
Measurement for payment will be made per each complete vaultthat has been
performed.
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Bid Item C8–Aerated Sludge Basin Drain Line
Payment shall include all work required to furnish and install the 12-inch PVC
Aerated Sludge Basin Drain Line including DIP fittings, couplings, and
appurtenances, excavation and backfill, complete and in place,as described in
the specifications and shown in the 01-Series drawings, except for items that
are described in the other Bid Items.
Measurement for payment will be made per linear foot of the work that has
been performed.
Bid Item C9–Septage Hauler Dump StationDrain Line
Payment shall include all work required to furnish and install the 6-inch PVC
Aerated Sludge Basin Drain Line including DIP fittings, couplings, and
appurtenances, excavation and backfill, complete and in place,as described in
the specifications and shown in the 01-Seriesand 05-Seriesdrawings, except
for items that are described in the other Bid Items.
Measurement for payment will be made per linear foot of the work that has
been performed.
Bid Item C10–72-inch Manholes
Payment shall include all work required to furnish and install the two 72-inch
manholes including connections, fittings, and appurtenances as described in
the specifications and shown in the 01-Series drawings, except for items that
are described in the other Bid Items.
Measurement for payment will be made per each manholethat has been
performed.
Bid Item C11–Fiber Optic DuctBank
Payment shall include all work required tofurnish and install the Fiber Optic
Ductbank along the southernproperty line, complete in place, including any
required concrete encasement and reinforcement, as shown in the 01-Series
drawings and described in the specifications, except for items that are
described in the other Bid Items.
Measurement for payment will be made per linear footof the work that has
been performed.
Resaca Lift Station Improvements and Odor Control System
Bid Item D1–Resaca Lift Station Odor Control Demolition
Payment shall include all work required for the demolition of the existing odor
control system including but not limited to all piping, electrical, and
appurtenances, at Resaca Lift Station as shown in the 04-Series drawings and
described in the specifications, except for items that are described in the other
Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item D2 –Resaca Lift Station Odor Control
Payment shall include all work required to construct, furnish, install and place
in service the proposed odor control unit for the Resaca Lift Stationincluding
fans, sample assembly, hose station, fittings, appurtenances, and electrical
conduits and wiringas described in the 04-Series drawings and specifications,
except for items that are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
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Bid Item D3–Odor Control Concrete Piers
Payment shall include all work required to furnish and install the 24-inch
diameter by 42 feet longConcrete Piers for the Odor Control System as shown
in the 04-Series drawings and described in the specifications, except for items
that are described in the other Bid Items.
Measurement for payment will be made per vertical linear footof the work that
has been performed.
Bid Item D4–Odor Control Concrete Slab and Equipment Pads
Payment shall include all work required to furnish and install the concrete slab,
mow strip, and equipment pads for the Odor Control System at Resaca Lift
Station, including reinforcement, appurtenances, and finishing complete in
place, as shown in the 04-Series drawings and described in the specifications,
except for items that are described in the other Bid Items.
Measurement for payment will be made per cubic yardof the work that has
been performed.
Bid Item D5–Odor Control Electrical Panels Canopy
Payment shall include all work required to furnish and install the canopyfor the
Odor Control Systemelectrical and control panelsat Resaca Lift Station,
includingsupports, anchor bolts, and appurtenances, as shown in the 04-Series
drawings and described in the specifications, except for items that are
described in the other Bid Items.
Measurement for payment will be made per lump sumof the work that has
been performed.
Bid Item D6–Odor Control FRP
Payment shall include all work requiredto furnish and install the 18-inchFRP
ductwork for the Odor Control System including but not limited to fittings,
joints, pipe supports, dampers, and appurtenances, as shown in the 04-Series
drawings and described in the specifications,except for items that are
described in the other Bid Items.
Measurement for payment will be made per linear footof the work that has
been performed.
Bid Item D7–Odor Control System, PVC Pipe,2-inchand Smaller
Payment shall include all work required to furnish and install PVC pipe 2-inchor
less in diameter for the Odor Control System including but not limited to
fittings, joints, valves, heat tracing, insulation, and appurtenances, as shown in
the 04-Series drawings and described in the specifications,except for items
that are described in the other Bid Items.
Measurement for payment will be made per linear footof the work that has
been performed.
Bid Item D8–Odor Control System, PVC Pipe,Greater than 2-inch
Payment shall include all work required to furnish and install PVC pipe greater
than 2-inchin diameter for the Odor Control System including but not limited to
fittings, joints, valves, heat tracing, insulation, and appurtenances, as shown in
the 04-Series drawings and described in the specifications, except for items
that are described in the other Bid Items.
Measurement for payment will be made per linear footof the work that has
been performed.
Bid Item D9 –Resaca Lift Station and Odor Control System Electrical, Instrumentation
and Controls
Payment shall include all work required to furnish and install the Odor Control
System electrical and instrumentation, including but not limited to wire,
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conduit, fittings, panels, ductbank, and all appurtenances, as shown in the 04-
Series drawings and described in the specifications, complete and operational,
except for items that are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item D10–Generator PLC
Payment shall include all work required to furnish and install the PLC
replacement for the Generator ATSas shown in the 04-Series Drawings and
described in the contract documents, complete and in operation, except for
items that are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
workas that has been performed.
Septage HaulerDumpStation
Bid Item E1 –Septage Receiving Station
Payment shall include all work required to furnish and installthe Septage
Receiving Stationequipment per SECTION 46 21 83 SEPTAGE RECEIVING
STATION andas described in the 05-Series drawings and specifications, except
for items that are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item E2–Septage Hauler DumpStation Washwater Piping
Payment shall include all work required to furnish and install the 2-inchPVC
SCH. 80 washwater piping, including fittings and appurtenancesas shown in
the 05-Series drawings and described in the specifications, except for items
that are described in the other Bid Items.
Measurement for payment will be made per linear foot of the work that has
been performed.
Bid Item E3–Septage Hauler Dump StationDIP Piping
Payment shall include all work required to furnish and install the 6-inchDIP
Pipe (Class 350) piping, including fittings, supports and appurtenances as
shown in the 05-Series drawings and described in the specifications, except for
items that are described in the other Bid Items.
Measurement for payment will be made per linear footof the work that has
been performed.
Bid Item E4 –Septage Hauler DumpStation Piers
Payment shall include all work required to furnish and install the 24-inch
diameterby 39-feet long Concrete Piers for the septage hauler dumpstation as
shown in the 05-Series drawings and described in the specifications, complete
in place, except for items that are described in the other Bid Items.
Measurement for payment will be made per vertical linear footof the work that
has been performed.
Bid Item E5–Septage Hauler Dump Station Concrete Slab and Equipment Pads
Payment shall include all work required to furnish and install the concrete slab,
mow strip, and equipment pads for the Odor Control System at Resaca Lift
Station, including reinforcement, appurtenances, and finishing complete in
place, as shown in the 04-Series drawings and described in the specifications,
except for items that are described in the other Bid Items.
Measurement for payment will be made per cubic yardof the work that has
been performed.
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Bid Item E6–Septage Receiving Station Electrical and Instrumentation
Payment shall include all work required to furnish and install the electrical,
instrumentationand controlequipment for the Septage Receiving Station as
shown in the 05-Series drawings and described in the specifications, complete
in place and operational, except for items that are described in the other Bid
Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Headworks
Bid Item F1–Headworks Work
Payment shall include all work required at the Headworks including, but not
limited to,demolition,furnishing and installation ofgrit classifier equipment,
detailed equipment and facility rehabilitation, openings in concrete wall
parapets, control room FRP platform, wall and ceiling, complete and placed in
operation, as shown on the in the 11-Series drawings and described in the
specifications, except for items described in other Bid Itemsbelow. The
quantities listed for the separate bid items described below are estimates. Any
additional quantities required to complete the work as shown on the Drawings
are included in this lump sum amount.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item F2–Headworks Washwater Piping
Payment shall include all 1-inch Schedule 80 PVC furnished and installed as
detailed in the specifications and shown on the11-Seriesdrawings, including
fittings, valves, insulation, couplings, appurtenances, and supports, for the
Headworks Washwater Piping, except for items that are described in the other
Bid Items.
Measurement for payment will be made per linear footof the work that has
been performed.
BidItem F3–Headworks Splitter BoxEffluent ChamberCoating
Payment shall include all work required to coat the Headworks Splitter Box
Effluent Chambersasdetailed in the specifications and shown on Drawing 11-
M-06 including cleaning, concrete preparation, and coating preparation,
coating, and touch up as required, except for items that are described in the
other Bid Items.
Measurement for payment will be made per square footof the work that has
been performed.
Bid Item F4–Expansion Joint Sealing System
Payment shall include all work required to furnish and installthe expansion
joint sealing systemin the Splitter BoxEffluent Chambers as shown on Drawing
11-M-06per SECTION 07 92 00JOINT SEALANT,Item 2.2.H., complete in
place.
Measurement for payment will be made per linear foot of material installed,
complete in place, that has been performed.
Bid Item F5–Headworks Building Electrical
Payment shall include all work required for demolition and to furnish and install
the electrical and instrumentation improvements at the Headworks Building
including conduit, wire, receptacles, heat trace, and panels, asdetailed in the
specifications and shown on the11-Seriesdrawings., except for items that are
described in the other Bid Items.
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Measurement for payment will be made per lump sum as a percentage of the
Work that has been performed.
Aeration Basin
Bid Item G1–Aeration Basin Work
Payment shall include all work required at the Aeration Basins as shown on the
in the 21-Series drawings and described in the specifications, except for items
described in other Bid Itemsbelow. The quantities listed for the separate bid
items described below are estimates. Any additional quantities required to
complete the work as shown on the Drawings are included in this lump sum
amount.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item G2–Aeration BasinEast WallSupport Columns
Payment shall include all work required to furnish and install the hot-dip
galvanized steel support columnsfor the Aeration Basin effluent channel on the
east wall,complete in place,except for items that are described in the other
Bid Items.
Measurement for payment will be made per eachsupport columns installed.
Bid Item G3–Aeration Basin Exterior Effluent Trough Leveling
Payment shall include all work required to furnish and install the exterior
effluent trough leveling for the Aeration Basin troughs as shown in the 21-
Series drawings, complete in place, except for items that are described in the
other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item G4–Micropile Foundations
Payment shall include all work required to furnish and install the micropile
foundations as shown in the 21-Series drawings at the depth determined by the
micropile Contractor,complete in place,except for items that are described in
the other Bid Items.
Measurement for payment will be made per each foundationthat has been
performed.
Bid Item G5–Sacrificial Micropile Verification Load Testing
Payment shall include all work required for the load testingas described in the
drawings and specifications in SECTION 31 62 18, except for items that are
described in the other Bid Items.
Measurement for payment will be made per each test.
Bid Item G6–Micropile Proof Load Testing
Payment shall include all work required for the load testingas described in the
drawings and specifications in SECTION 31 62 18, except for items that are
described in the other Bid Items.
Measurement for payment will be made per each test.
Bid Item G7–Concrete Pile Cap
Payment shall include all work required to furnish and install the concrete pile
cap at the Aeration Basinas shown in the 21-Series drawings,complete in
place,except for items that are described in the other Bid Items.
Measurement for payment will be made per cubic yardof the work that has
been performed.
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Bid Item G8–Expansion Joint Sealing System
Payment shall include all work required to furnish and installthe expansion
joint sealing systemfor the longitudinal and lateral construction joints in the
Aeration Basins as shown on 21-Series drawings and per SECTION 07 92 00
JOINT SEALANT,Item 2.2.H., complete in place.
Measurement for payment will be made per linear foot of material installed,
complete in place, that has been performed.
Bid Item G9–Aeration Basin Duplex Piping
Payment shall include all work required to furnish and install the 2205 Duplex
Stainless Steel Piping, including fittings, couplings, and appurtenances in the
Aeration Basins as shown in the 21-Series drawings, complete in place, except
for items that are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item G10–Blower Instrumentationand ControlsImprovements
Payment shall include all work required to furnish and install the electrical,
instrumentation and controls improvements as shown in the 22-Series drawings
and described in the contract documents,complete in place and operational,
except for items that are described in the other Bid Items.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
RAS/WAS Pump Station
Bid Item H1–RAS/WAS Pumps
Payment shall include construction of all work requiredat the RAS/WAS Pump
Stationas described in the specifications and shown in the 25-Series drawings,
except for items that are described in the separateBid Itembelow.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
Bid Item H2–RAS/WAS Pump Station Electrical and Instrumentation
Payment shall include all work required to furnish and install the electrical and
instrumentation improvementsfor the RAS/WAS Pump Stationas described in
the specifications and shown in the 25-Series drawings.
Measurement for payment will be made per lump sum as a percentage of the
work that has been performed.
PRODUCTS (NOT USED)
EXECUTION (NOT USED)
END OF SECTION
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01 57 00TEMPORARY CONTROLS
GENERAL
1.1WORK INCLUDED
Provide labor, materials, equipment,and incidentals necessary to construct temporary
facilities to provide and maintain control over environmental conditions at the Site.
Remove temporary facilities when no longer needed.
Construct temporary impounding works, channels, diversions, furnishing and operation of
pumps, installing piping and fittings, and other construction for control of conditions at the
Site. Remove temporary controls at the end of the Project.
Provide a Storm Water Pollution Prevention Plan (SWPPP) as required by Texas Pollutant
Discharge Elimination System (TPDES) General Permit No. TXR150000 for stormwater
discharges from construction activitiesas applicable to the nature and size of the Project.
Comply with all requirements ofthe Texas Commission on Environmental Quality (TCEQ)
and Laws and Regulations. File required legal notices and obtain required permits prior to
beginning any construction activity.
Provide labor, materials, equipment, and incidentals necessary to prevent stormwater
pollution for the duration of the Project. Provide and maintain erosion and sediment
control structures as required to preventive sediment and other pollutants from the Site
from entering any stormwater system including open channels. Remove pollution control
structures when no longer required to prevent stormwater pollution.
1.2QUALITY ASSURANCE
Construct and maintain temporary controls with adequate workmanship using durable
materials to provide effective environmental management systems meeting the
requirements of the Contract Documents and Laws and Regulations. Use materials that
require minimal maintenance to prevent disruption of construction activities while
providing adequate protection of the environment.
Periodically inspect systems to determine that they are meeting the requirements of the
Contract Documents.
1.3DOCUMENT SUBMITTAL
Provide documents requiring approval by the OPT as Shop Drawingsin accordance with
Article 25 of SECTION 00 72 00 GENERAL CONDITIONS.
Provide copies of notices, records,and reports required by the Contract Documents or
Laws and Regulations as Record Datain accordance with Article 26 of SECTION 00 72 00
GENERAL CONDITIONS.
1.4STANDARDS
Provide a SWPPP that complies with all requirements of TPDES General Permit No.
TXR150000 and any other applicable Laws and Regulations.
Perform Work to comply with the City of Corpus Christi Code of Ordinances, Part III,
Chapter 14, Article X -titled “STORM WATER QUALITY MANAGEMENT PLANS” and any
other applicable Laws and Regulations.
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1.5PERMITS
As applicable, submit the following to the TCEQ and the Operator of any Municipal
Separate Storm Sewer System (MS4) receiving stormwaterdischarges from the Site:
Notice of Intent (NOI) at least 48 hours prior to beginning construction activity.
Construction activity may commence 24 hours after the submittal of an electronic
NOI.
Notice of Change (NOC) letter when relevant facts or incorrect information was
submitted in the NOI, or if relevant information in the NOI changes during the course
of construction activity.
Notice of Termination (NOT) when the construction Project has been completed and
stabilized.
Post a copy of the NOI at the Site in a location where it is readily available for viewing by
the general publicand as required by Laws and Regulationsprior to starting construction
activities and maintain the posting until completion of the construction activities.
Maintain copies of a schedule of major construction activities, inspection reports, and
revision documentation with the SWPPP.
1.6STORMWATERPOLLUTION CONTROL
Comply with the current requirements of TPDES General Permit No. TXR150000as set forth
by the TCEQfor the duration of the Projectas applicable to the nature of the work and the
total disturbed area:
Develop a SWPPP meeting all requirements of the TPDES General Permit.
Submit of a Notice of Intent to the TCEQ.
Develop and implement appropriate Best Management Practices as established by
local agencies of jurisdiction.
Provide all monitoring and/or sampling required for reporting to the TCEQ.
Submit reports to the TCEQas required as a condition of the TPDES General Permit.
Submit copies of the reports to the Designeras Record Datain accordance with
Article 26 of SECTION 00 72 00 GENERAL CONDITIONS.
Retain copies of these documents at the Site at all times for review and inspection by
the OPT or regulatory agencies. Post a copy of the permit as required by Laws and
Regulations.
Assume sole responsibilityfor implementing, updating, and modifying the TPDES
General Permit per Laws and Regulationsfor the SWPPPand Best Management
Practices.
Use forms required by the TCEQto file the Notice of Intent. Submit the Notice of Intent at
least 2 days prior to the start of construction. Develop the SWPPPprior to submitting the
Notice of Intent. Provide draft copies of the Notice of Intent, SWPPP, and any other
pertinent TCEQ submittal documents to Owner for review prior to submittal to the TCEQ.
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Return any property disturbed by construction activities to either specified conditions or
pre-construction conditions as set forth in the Contract Documents. Provide an overall
erosion and sedimentation control system that will protect all undisturbed areas and soil
stockpiles/spoil areas. Implement appropriate Best Management Practices and techniques
to control erosion and sedimentation and maintain these practices and techniques in
effective operating condition during construction. Permanently stabilize exposed soil and
fill as soon as practical during the Work.
Assume sole responsibility for the means, methods, techniques, sequences, and procedures
for furnishing, installing, and maintaining erosion and sedimentation control structures and
procedures and overall compliance with the TPDES GeneralPermit. Modify the system as
required to effectively control erosion and sediment.
Retain copies of reports required by the TPDES GeneralPermit for 3 years from date of
Final Completion.
1.7POLLUTION CONTROL
Prevent the contamination of soil, water,or atmosphere by the discharge of noxious
substances from construction operations. Provide adequate measures to prevent the
creation of noxious air-borne pollutants. Prevent dispersal of pollutants into the
atmosphere. Do not dump or otherwise discharge noxious or harmful fluids into drains or
sewers, nor allow noxious liquids to contaminate public waterways in any manner.
Provide equipment and personnel and perform emergency measures necessary to contain
any spillage.
Contain chemicals in protective areas and do not dump on soil. Dispose of such
materials at off-site locations in an acceptable manner.
Excavate contaminated soil and dispose at an off-site location if contamination of the
soil does occur. Fill resulting excavations with suitable backfill and compact to the
density of the surrounding undisturbed soil.
Provide documentation to the Owner which states the nature and strength of the
contaminant, method of disposal, and the location of the disposal site.
Comply with Laws and Regulations regarding the disposal of pollutants.
Groundwater or run-off water which has come into contact with noxious chemicals, sludge,
or sludge-contaminated soil is considered contaminated. Contaminated water must not be
allowed to enter streams or water courses, leave the Site in a non-contained form,or enter
non-contaminated areas of the Site.
Pump contaminated water to holding ponds constructed by the Contractor for this
purpose, or discharge to areas on the interior of the Site, as designated by the OAR.
Construct temporary earthen dikes or take other precautions and measures as
required to contain the contaminated water and pump to a designated storage area.
Wash any equipment used for handling contaminated water or soil within
contaminated areas three times with uncontaminated water prior to using such
equipment in an uncontaminated area. Dispose of wash water used to wash such
equipment as contaminated water.
EARTH CONTROL
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Remove excess soil, spoil materials,and other earth not required for backfill at the
time of generation. Control stockpiled materials to eliminate interference with
Contractor and Owner’s operations.
Dispose of excess earth off the Site. Provide written approval from the property
owner for soils deposited on private property. Obtain approval of the Owner if this
disposal impacts the use of Site or other easements.
1.8OZONE ADVISORY DAYS(NOT APPLICABLE)
Do not conduct roofing, priming,or hot-mix paving operations, except for repairs, on days
the City Engineer has notified Contractor that an ozone advisory is in effect. An extension
of time will be allowed for each day for which priming or hot mix paving was scheduled,
crews were prepared to perform this Work and the City Engineer issued ozone alert
prevents this Work. Contractor will be compensated at the unit price indicated in the Bid
for each day for which an extension of time was granted due to an ozone alert.
1.9MANAGEMENT OF WATER
Manage water resulting from rains or ground water at the Site. Maintain trenches and
excavations free of water at all times.
Lower the water table in the construction area by acceptable means if necessary to
maintain a dry and workable condition at all times. Provide drains, sumps, casings, well
points, and other water control devices as necessary to remove excess water.
Provide continuous operation of water management actions. Maintain standby equipment
to provide proper and continuous operation for water management.
Ensure that water drainage does not damage adjacent property. Divert water into the
same natural watercourse in which its headwaters are located, or other natural stream or
waterway as approved by the Owner. Assume responsibility for the discharge of water
from the Site.
Remove the temporary construction and restore the Site in a manner acceptable to the
OAR and to match surrounding material at the conclusion of the Work.
1.10DEWATERING
This item is considered subsidiary for all dewatering methods other than “well pointing” to
the appropriate bid items as described in the Bid Form where dewatering is needed to keep
the excavation dry, as approved by the Designer, and shall include all costs to provide a dry
foundation for the proposed improvements.
Storm water that enters an excavation can be pumped out as long as care is taken to
minimize solids and mud entering the pump suction and flow is pumped to a location that
allows for sheet flow prior to entering a storm water drainage ditch or storm water inlet.
An alternative to sheet flow is to pump storm water to an area where ponding occurs
naturally without leaving the designated work area or by a manmade berm(s) prior to
entering the storm water system. Sheet flow and ponding is to allow solids screening
and/or settling prior to entering a storm water conduit or inlet.
Storm water or groundwater shall not be discharged to private property without
permission. It is the intent that Contractor discharges groundwater primarily into the
existing storm water system, provided that the quality of groundwater is equal to or better
than the receiving stream, the Corpus Christi Bay.
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Testing of groundwater quality is to be performed by the Contractor, at the Contractor’s
expense, prior to commencing discharge and shall be retested by the Contractor, at the
Contractor’sexpense, a minimum of once a week. Contractor shall coordinate with the
Owner on all testing. Tests will also be performed as each new area of construction is
started.
Another option for disposal of groundwater by Contractor would include pumping to the
nearest wastewatersystem. If discharging to temporary holding tanks and trucking to a
wastewateror wastewater plant, the costs for these operations shall be negotiated. Other
groundwater disposal alternatives or solutions may be approved by the Designer on a case
by case basis.
Prior to pumping groundwater from a trench to the wastewatersystem the Contractor shall
contact Wastewater Pre-treatment Coordinator at 826-1817 to obtain a “no cost” permit
from the Owner’s Waste Water Department. Contractorwill pay for any water quality
testing or water analysis cost required. The permit will require an estimate of groundwater
flow. Groundwater flow can be estimated by boring a hole or excavating a short trench
then record water level shortly after completion, allow to sit overnight,record water level
again, pump hole or trench dry to a holding tank or vacuum truck then record how long it
takes to fill to original level and overnight level.
1.11DISPOSAL OF CONTAMINATED GROUNDWATER–NOT APPLICABLE
An allowance will be included in the Bid for the unanticipated disposal of contaminated
groundwater. This allowance may not be needed but is provided in case contaminated
groundwater is encountered during the course of the Project and does not meet the water
quality requirements for discharge into the storm water or wastewater systems. This
allowance includes all materials, tools, equipment, labor, transportation, hauling,
coordination, and proper disposal of the contaminated water at an approved landfill, deep
water injection well, or other site as agreed to by the Designer. Suggested disposal
facilities would be US Ecology (USET) in Robstown, Texas or Texas Molecular in Corpus
Christi, Texas.
The payment for this Work will be based on the Contractor’s actual costs and will be
negotiated. Payment will not include costs associated with routine dewatering,which is
considered subsidiary to the appropriate bid items as described in Paragraph 1.11.
1.12DISPOSAL OF HIGHLY CHLORINATED WATER
Dispose of water used for testing, disinfection, and line flushing. Comply with Owner’s
requirements and Laws and Regulation regarding the disposal of contaminated water,
including water with levels of chlorine, which exceed the permissible limits for discharge
into wetlands or environmentally sensitive areas. Comply with the requirements of all
regulatory agencies in the disposal of all water used in the Project. Include a description
and details for disposal of this water in a Plan of Action per SECTION 01 35 00 SPECIAL
PROCEDURES. Do not use the Owner’s wastewatersystem for disposal of contaminated
water.
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1.13WINDSTORM CERTIFICATION
All affected materials and installation shall comply with Texas Department of Insurance
Requirements for windstorm resistant construction for design wind speed as required by
the current version of the International Building Code(IBC). When applicable, Contractor
shall be responsible for contracting with a licensed structural engineer in the State of Texas
to perform all inspections and provide documentation for windstorm certification to the
Texas Board of Insurance. The Contractor shall be responsible for providing all necessary
design/assembly documentation for all new windows, doors, louvers, etc. to the windstorm
engineer/inspectors required to conform with the requirements of the Texas Department
of Insurance.
The Citymay request the Contractor to obtain Windstorm Certification for the following
areas under the Bid Item Allowance A-5:
5
Biological Tower Type Odor Control System
Septage Receiving Station, and
Electrical Rack Canopy on sheet 05-E-01
PRODUCTS
2.1MATERIALS
Provide materials that comply with Laws and Regulations.
EXECUTION
3.1CONSTRUCTING, MAINTAINING AND REMOVING TEMPORARY CONTROLS
Construct temporary controls in accordance with Laws and Regulations.
Maintain controls in accordance with regulatory requirements where applicable, or in
accordance with the requirements of the Contract Documents.
Remove temporary controlswhen no longer required, but before the Project is complete.
Correct any damage or pollution that occurs as the result of removing controls while they
are still required.
END OF SECTION
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SECTION 0112 16
SEQUENCE OF CONSTRUCTION
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2GENERAL
Certain aspects ofconstruction of this Project mayoccurafter the facilityhas been started
up or while the facilityis operating to meet specifictreatment limits. The operations
necessary to meet these requirements are of higher priority than construction activities.
Schedules of connections, renovations and modifications required after startup shall be
submitted to the OWNER for approval, and all such items shall be coordinated throughout
the entire construction period. These schedules shall permit full and normal treatment and
conveyance of water.
The CONTRACTOR shall prepare and submit a project schedule within 15days ofthe
preconstruction meeting or within 7 days of notice to proceed, whichever comes first,
outlining the schedule and time requirements for each item involving an existing treatment
unit, piece of equipment, and conveyance system. No payment shall be made until these
items are received.
The CONTRACTOR shall notify the OWNER at leastfourteen(14)days in advance and again
three (3)days prior to beginning work on a particular area, and coordinate with the OWNER
the specific items to be isolated and duration for each. Obtain written approval from the
OWNER prior to each shutdown. High flow conditions or equipment outages may require
the rescheduling of an approved shutdown. Any cost associated with rescheduling will be
subsidiary to Project.
After startupand transfer of operation to the OWNER,the CONTRACTOR shall not operate
any valves or equipment in the facilityunless directed to do so by the OWNER.
Prior to beginning work, the CONTRACTOR shall have on-site all materials, equipment, and
personnel necessary to complete the work in the time scheduled. The CONTRACTOR shall
also perform all possible tasks to the most complete state possible prior to shutdowns. All
exposed bolts and nuts on valves or fittings which are to be disassembled shall be removed
and replaced one at a time prior to shutdown to assure as timely progress as possible.
Access to all components of the facilitymust be maintained at all times.
In general, new and existing equipment cannot be offline longer than one hour while piping
and electrical connections are being made. Longer shut downs for equipment may be
possible. Coordinate with OWNER.
Existing plugged pipelines, in which water has been standing, shall be cleaned of debris
prior to connecting to a new pipeline.
The CONTRACTOR shall coordinate and schedule each task necessary to complete all work
within the time allowed for the project. Specific connection coordination, shutdown, and out
of service (downtime) limitations, are described,but not limited to,the specific items listed
in PART 3.
The sequencing may require the CONTRACTOR to perform work such as installing temporary
or permanent plugs and/or diversion facilities in structures that are online. The specifics
related to flow diversion and temporary plugging means and methods are the responsibility
of the CONTRACTOR;however, the CONTRACTOR'Sproposed work operationsand
schedules shall be submitted to the OWNER for review. All costs for temporary piping and
pumping, pipe connections, and all related work shall be included in the Base Bid of the
project.
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FacilityPiping Interconnections Requirements. All testing ofpipes to be connected shall be
completed and test reports furnished to the ENGINEER prior to making connections.
Drain system connections should generally not require prior notification to proceed
unless the existing pipe must be temporarily plugged or blocked for the connection.
Plant water and potable water connections require advance notification and
concurrence from the OWNER prior to isolating or shutting down the system for
connection. Potable pipes should be flushed and pressure tested prior to connection
and disinfected following the connection. CONTRACTOR shall coordinate these items.
Reduce the number of shutdowns required for piping systemsby combining as many
connections at the same time as feasible.
Facilityprocess piping connections are critical and shall be fully coordinated,
expedited,and done in a continuous manner upon initiation. These pipes generally
do not have isolation valves or parallel pipes and require shutting down the treatment
process for connection.
Time shall be allowed for shutting down the process and dewatering the existing pipe
and/or basinin addition to the actual connection time. CONTRACTOR shall provide all
equipment, tools and labor to dewater the pipes for connections. This process water
shall be contained in the facilities and not allowed to discharge over the ground or to
the surface drainage systems.
All facilityshutdowns must be coordinated with and approved by the OWNER. OWNER
will not allow work to be performed in a series of shutdowns on back-to-back days.
Potable water piping shall be cleaned, disinfected, and tested prior to placing into
service. CONTRACTOR shall provide taps, flushing, and blow-off connections to flush
and disinfect each pipe section and treatment unit.
PRODUCTS (NOT USED)
EXECUTION
3.1CONSTRUCTION SEQUENCING:
Throughout construction the plant will need to remain in operation. The CONTRACTOR is
not prohibited from working on other areas of the plant unless that work requires
interruption of treatment units, equipment, piping, electrical power and communications, or
other ancillary items that would prevent operation of treatment units that must remain
online.
Resaca Lift Station Requirements:
The Resaca Lift Station shall remain online throughout the duration of construction.
The odor improvements may be completed at any time.
Controls of the pumps may be switched from existing to new such that the pumps in
one wet well compartment shall remain automatically operated from the existing
5
control system until the pumps in the other wet well compartment can be operated
automatically with the new control system. Contractor is responsible for not allowing
an overflow to occur during switchover.
Septage Receiving Station Requirements:
CONTRACTOR shallprovide temporarylocation for customers delivering septage to
the Plant prior to demolishing the existing septage dump station so that there is no
interruption in service for customers delivering septage to the Plant. Utilize the
existing drain line to connect temporary dump station.ensure there for more than 24
hours.
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The existing dump station shall remain in service until the new system is in operation.
Headworks Requirements:
At least one mechanical bar screen, washer/compactor and grit unit must remain
5
operational at all times for the duration of construction.
At least one mechanical bar screen and washer/compactor shall remain operational at
all times for the duration of construction. The existing grit classifier may be taken out
of service for a maximum period of 7 days in order to install and startup one of the
new grit classifiers. The new grit classifier must be operational by the end of the 7
days.
CONTRACTOR shallcoordinate the work in the aeration basin splitter boxes with the
work in the aeration basins. The CONTRACTOR shall isolate the corresponding
aeration splitter boxwith the aeration basin that is out-of-service for installation of
thenew drain line. The Contractor will utilize the aeration basin splitter box slide gate
to isolate the downstream splitter box.
Aeration Basin (AB) Requirements:
Work shall be completed in one aeration basin at a timebeginning with AB-4, which is
currently out of service.The support system being added to AB-4 east walland the
installation of the expansion joint sealant in AB-4 and the East Effluent Channelshall
be completed prior to bringing AB-4 back into service. Each aeration basin shall be
shut down only once to complete the work indicated in the Contract Documents.
There shall be a minimum of two weeks between the time one aeration basin is
brought back online and the next aeration basin is taken offline.
The OWNER shall drain the basins. The CONTRACTOR shall be responsible for
cleaning the basin prior to beginning structural, drain and piping modifications. The
CONTRACTOR shall assume that there is two feet of grit and sludge to be cleaned
from each basin.The basin shall be empty and cleaned for diffuser equipment
inspection. The contractor may use the existing drain for sludge washdown and
4
cleaning, however, due to the size of the drain, expect the process to take several
weeks. The contractor may also select to wash down and clean the sludge after
installation of the new drain. The contractor shall coordinate with the plant operations
on the rate of washdown using the new drain. The plant will require the washdown
and draining of solids to extend for atleast a week to send the solids through the
treatment process. If the Contractor installs the new drain first, then the Contractor
may just clean out the area around the drain needed to perform the work.
The CONTRACTOR shall have the Fine-Bubble Diffuser Manufacturer Representative
inspect the diffuser system in each basin following basin cleaning to identify pipe
repairs and diffuser replacement/adjustmentneeded. There will need to be four trips
by the Diffusers Manufacturer Representative, one for each basin. CONTRACTOR
shall perform repairs and diffuser replacement/adjustmentas identified by
Manufacturer Representative and agreed to by OWNER. Diffuser System Repair
Allowance shall be used for cost of repair work.Field visits by manufacturer
representative to inspect diffusers shall be included in Bid Item Gl. Manufacturer of
4
existing diffusers is Sanitaire, Inc.
Expansion Joint Sealant Installation in AB Effluent Channel.
CONTRACTOR shall install expansion joint sealant in accordance with Structural
Drawingsand Manufacturer instructions.
For the East Effluent Channel Location:
Installation of expansion joint sealant in the east effluent channel location
shall occur after installation of the east wall support system as shown on
Sheet 21-S-05.
Prior to installation, CONTRACTOR shall install coffer dams on both sides
of theexpansion joint location to be able to drain that section of the
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effluentchanneland preparethe concrete surfacefor expansion joint
sealant installation.
CONTRACTOR shall use bypass pumps to pump mixed liquor around the
expansion joint locationduring installation of the expansion joint sealant.
The pumping capacity shallbe capable of pumping the maximum daily dry
weather flow during plus the RAS flow to the aeration basins. This
pumping capacity is approximately 10 MGD, but may need to be more
depending on actual conditions during the bypass pumping event.
For the North Effluent Channel Location:
Installation of expansion joint sealant in the north effluent channel location
shall coincide with the expansion joint sealant in AB-3.
Prior to installation, CONTRACTOR shall install coffer dams on both sides
of the expansion joint location to be able to drain that section of the
effluent channel and prepare concrete surface for expansion joint sealant
installation.
CONTRACTOR shall use bypass pumps to pump mixed liquor around the
expansion joint location during installation of the expansion joint sealant.
The pumping capacity shall be capable of pumping the maximum daily dry
weather flow plus the RAS flow to the aeration basins. This pumping
capacity is approximately 10 MGD but may need to be more depending on
actual conditions during the bypass pumping event.
Secondary Clarifier Requirements:
Work shall be completed in one secondary clarifier at a time. Each secondary clarifier
shall be shut down only once to complete the work indicated in the Contract
Documents.
Shutdowns shall only occur during dry weather. Shutdowns are not allowed during
wet weather events. CONTRACTOR shall coordinate with the OWNER prior to
beginning work in this area to ensure sufficient capacity is available.
The OWNER shall drain the basins. The CONTRACTOR shall be responsible for
cleaning the basin, as required, prior to beginning demolition work. There should not
be significant amounts of sludge remaining in the clarifier after draining the basin.
4
The contractor may use a trash pump or other means to clean the basin. The trash
pump may discharge into scum box.
RAS Pump Requirements:
A minimum of two RAS pumps shall remain operational during the pump replacement.
Pipe Connection Requirements:
There are two proposed connections to the 48-inch raw sewage influent line. These
connections shall be made with manholes as shown on the Drawings. During the
connections, the existing 48-inch raw sewage influent line must remain in service.
END OF SECTION
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SECTION 01 35 73
DELEGATED DESIGN PROCEDURES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. General provisions for delegated design services.
2. Coordination of delegated designs with other Work.
3. Qualifications requirements for delegated design professionals.
4. Limitations on Engineer’s review of delegated design Submittals.
5. Responsibilities of delegated design professionals.
B. Scope:
6. Where delegated design is specifically Contractor’s responsibility in accordance with
the Contract Documents, Contractor shall provide labor, services, other effort, and
pay all costs necessary and required to perform delegated design services for Work
that will be part of the completed Project as a functioning whole.
7. Perform delegated design Work in accordance with the Contract Documents,
delegated design Action Submittals approved by Engineer, and Shop Drawings,
product data Submittals, and Samples approved by the associated delegated design
professional.
8. Contractor’s correction period, general warranty and guarantee, and obligations for
safety and protection apply to delegated design Work to the same extent such
provisions apply to all other Work under the Contract.
9. Specifications requiring delegated design services include, but are not necessarily
limited to, the following:
a. Section 03 15 19 - Anchorage to Concrete.
b. Section 31 62 18 Micropiles
10. Not Delegated Design: The following are not delegated design and are not covered
by this Section:
a. Contractor’s use of design professionals for: (1) temporary construction or
temporary facilities not part of the completed Project as a functioning whole, or
(2) Contractor’s means, methods, procedures, techniques, and sequences of
construction and safety and protection measures incident thereto.
Requirements applicable to such professional services are in Section 01 71 23 -
Field Engineering.
b. Certain final designs that, in accordance with commonly accepted practice, are
typically prepared by unlicensed, unregistered individuals, including for
manufactured or fabricated systems, components or assemblies, not acting
under the supervisory control of the design professional in responsible charge,
but who commonly possess appropriate certification from a relevant industry
organization, together with appropriate training and experience.
C. Related Requirements:
11. Supplementary Conditions – Professional liability insurance requirements for Micropile
Contractor’s Professional Engineer or Consultant Designer’s Professional Engineer.
12. Section 01 71 23 - Field Engineering.
13. Sections of Divisions 02-49 where delegated design Work is required.
1.2 REFERENCES
A. Terminology:
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1. Terminology indicated below are not defined terms and are not indicated with initial
capital letters but, when used in this Section and Specifications of Division 02-49
where delegated design Work is required, have the meaning indicated below:
a. “Delegated design” means preparing the final design of part of the completed,
permanent Work by one or more delegated design professionals, in accordance
with the Contract Documents. The terms “delegated design”, “delegated
design services”, “delegation of design responsibility”, and similar or derivative
terms have the same meaning.
b. “Delegated design professional” means the licensed and registered engineer,
architect, geologist, or other design professional retained by or employed by
Contractor, Subcontractor, or Supplier to perform delegated design services for
delegated design Work and possessing appropriate experience and
qualifications for such delegated design services.
c. “Delegated design Work” means delegated design services, associated
construction, and related Work.
d. “Instruments of service”, relative to delegated designs, means delegated
design professional’s: (1) certifications (including delegated design
professional’s certification of compliance, as required in this Section, and other
certifications required of delegated design professional), (2) reports (where
required), (3) design drawings, (4) design specifications, (5) other documents
specifically indicated as delegated design professional’s “instruments of service”
in the Contract Documents, and (6) documents modifying a delegated design
(after Engineer’s approval of the original delegated design Submittals).
“Instruments of service” are to be sealed, signed, and dated by delegated
design professional and expressly required as Submittals. Shop Drawings
sealed and signed by delegated design professional are delegated design
professional’s “instruments of service”.
1.3 GENERAL PROVISIONS CONCERNING DELEGATED DESIGN SERVICES
A. Delegated Designs - General:
B.
1. This Section augments the requirements of the General Conditions, as may be
amended by the Supplementary Conditions, and other provisions of the Contract
Documents regarding Contractor’s responsibilities for delegated design Work.
2. Delegated design professionals or their employer shall furnish professional liability
insurance. Provisions on professional liability insurance are set forth in the
Supplementary Conditions. Submit through Contractor appropriate documentation of
professional liability insurance.
1.4 ADMINISTRATIVE REQUIREMENTS
A. Coordination:
1. Coordination - General:
a. Contractor shall coordinate the services of delegated design professionals with
all other elements of the Work.
b. Contractor has full responsibility for scheduling delegated designs and all
related Work.
c. Allow sufficient time in Progress Schedule for performance of delegated design
services, including requests for interpretation or clarification between delegated
design professional and Contractor and between Contractor and Engineer.
2. Coordination of Delegated Design Work’s Connections to Other Work:
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a. Where delegated design Work connects to other Work designed by Engineer,
existing construction, or both, the delegated design Work shall be consistent
with the other Work and existing construction to which delegated design Work
connects, and adjacent construction.
b. Submit details, loading, anchorage, and other coordinating information
necessary to for the delegated design Work to properly interface with Work
designed by Engineer.
c. Changes in the Work, whether designed by Engineer, designed by delegated
design professional, or existing construction, necessary as a result of the
delegated design are ineligible for increase in Contract Price or Contract Times,
unless: (1) otherwise agreed by both Engineer and Owner, or (2) expressly
indicated otherwise elsewhere in the Contract Documents for the associated
delegated design Work.
d. Changes requiring extra compensation, time, or both arising from delegated
design aspects needed for convenience of Contractor, Subcontractor, or
Supplier, are not grounds for increase in Contract Price or Contract Times.
3. Coordination of Submittals, Fabrication, Production, and Shipment:
a. Do not release for raw materials procurement, fabrication, production, and
shipment to the Site materials, equipment, or systems designed by delegated
design professional until the associated delegated design professional has
reviewed and approved all associated Shop Drawings, product data, Samples,
and (relative to shipment) source quality control Submittals, and such
Submittals have been delivered to and accepted by Engineer.
b. Allow sufficient time in the Progress Schedule for required Submittals and
required actions by delegated design professionals and Engineer.
B. Pre-design Conference:
4. Where indicated in the Division 02-49 Specifications section(s) where delegated
design Work is required, for each such delegated design, participate in a pre-design
conference.
5. Date, Time, and Location:
a. Obtain Engineer’s acceptance of delegated design professional’s qualifications
statement prior to pre-design conference.
b. Submit and obtain Owner’s acceptance of delegated design professional’s
documentation of professional liability insurance prior to associated pre-design
conference.
c. Participate in pre-design conference prior to commencing preparation of the
delegated design’s calculations and instruments of service Submittals.
Optimally, pre-design conference should be after the delegated design
professional has: (1) completed its initial Site visit or accepts responsibility for
not doing so; (2) reviewed applicable information and Laws and Regulations;
and (3) is familiar with the performance and design criteria (indicated in the
Contract Documents) that the subject delegated design must satisfy.
d. Contractor and Engineer will mutually establish the date and time for the pre-
design conference.
e. Pre-design conference will be held either via conference call hosted by Engineer
or in-person at the Site or other location mutually agreed upon by Contractor
and Engineer.
6. Required Participants: The following shall participant in the pre-design conference:
a. Contractor’s Team:
1) Contractor’s project manager.
2) Contractor’s Site superintendent.
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3) Delegated design professional retained for the subject delegated design
Work. Required participant is the individual that will serve in responsible
charge of the delegated design, in accordance with Laws and
Regulations.
4) As applicable, project manager of Subcontractor or Supplier that retained
the delegated design professional.
5) Representatives of other Subcontractors and Suppliers of related Work,
invited by Contractor.
b. Engineer:
1) Engineer’s project manager or designee.
2) Engineer’s design professional in responsible charge (if other than
Engineer’s project manager or designee) who sealed and signed the
Drawings and Specifications presenting the performance and design
criteria the subject delegated design Work must satisfy.
3) Engineer’s other team members deemed necessary by Engineer.
4) Resident Project Representative (if any).
c. Owner:
1) Owner’s project manager or designee.
2) Owner’s Site Representative (if any).
3) Others invited by Owner.
7. Engineer will chair pre-design conference and prepare and distribute a record of the
conference to all pre-design conference participants and others as deemed
appropriate by chair of the pre-design meeting.
8. Agenda: Pre-design conference participants shall be prepared to discuss in detail the
following:
a. Introduction of participants.
b. Review of Contract’s delegated design requirements and procedures.
c. Performance and design criteria the subject delegated design Work must
satisfy.
d. Requirements for Submittals for delegated design Work.
1) Instruments of service of delegated design professional, and Engineer’s
associated, limited review.
2) Delegated design professional’s responsibility for reviewing and
approving all other Submittals resulting from the subject delegated
design Work.
e. Schedule for preparation and submittal of: (1) delegated design professional’s
instruments of service Submittals, (2) Shop Drawings, product data, Samples,
and testing plans (as applicable), (3) fabrication or production, and (4)
shipment of related materials, equipment, and systems.
f. Other responsibilities of delegated design professional, as indicated in the
Contract Documents.
1.5 QUALITY ASSURANCE
A. Qualifications:
1. Delegated Design Professionals:
a. Each delegated design professional shall possess not less than the minimum
qualifications set forth in this provision. Where the Specifications for the
associated delegated design Work establish more-stringent qualifications
requirements, comply with the more-stringent requirements.
b. Each delegated design professional shall comply with all of the following:
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1) Legally qualified, as both an individual and as a business entity, to
practice the associated design discipline(s) in the jurisdiction where the
Site is located, including possessing current, valid license and registration
for the design discipline(s) for which the delegated design professional
will render its services on the Project.
2) Possess not less than five years of experience in the subject design
discipline(s).
3) Served as design professional in responsible charge on not less than five
other designs similar in scope and complexity to the Work for which
delegated design professional is retained on the Project; construction of
such prior projects shall be complete by the start of the Project’s
construction.
c. Summary of Qualifications: Submit to Engineer summary of delegated design
professional’s experience and qualifications, including:
1) Evidence of coverage under appropriate professional liability insurance in
accordance with the Contract Documents.
2) Evidence of delegated design professional’s ability to legally conduct
business as a design professional in the same jurisdiction as the Site, as
a business entity.
3) Copy of delegated design professional’s current, valid personal design
professional license and registration for the same jurisdiction as the Site.
Such documents shall indicate the individual’s name, license or
registration number, and dates for which the license or registration is
valid.
4) Other information reasonably requested by Engineer.
1.6 GENERAL PROVISIONS FOR DELEGATED DESIGN SUBMITTALS
A. Under the Division 02-49 Specifications section(s) where delegated design Work is required,
furnish to Engineer Submittals such as:
1. Action Submittals:
a. Delegated design professional’s instruments of service Submittals.
2. Informational Submittals:
a. When delivered to Engineer, the following must bear delegated design
professional’s Submittal approval stamp:
1) Shop Drawings, product data Submittals, Samples, testing plans.
2) Results of source quality control and field quality control activities.
b. Delegated design professional’s calculations.
c. Other Informational Submittals required for the subject delegated design Work.
B. Limitations of Engineer’s Review of Delegated Design Submittals:
3. Delegated Design Professional’s Instruments of Service Submittals:
a. Engineer’s review of delegated design instruments of service Submittals is for
the limited purposes indicated in\[the General Conditions, as maybe modified by
the Supplementary Conditions.
b. The following disclaimer applies to Engineer’s responses to delegated design
professional’s instruments of service Submittals:
1) Engineer’s review and approval of delegated design instruments of
service is only for the limited purpose of verifying that performance and
design criteria given in the Contract were used in the delegated design
and checking for compliance with the Engineer’s design concept
expressed in the Contract Documents.
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2) Contractor is solely responsible for complying with: the Contract
Documents, Subcontractor and Supplier instructions consistent with the
Contract Documents, Owner’s directions, and Laws and Regulations.
3) Contractor is solely responsible for obtaining, correlating, confirming,
and correcting dimensions at the Site; quantities; information and
choices pertaining to fabrication processes; means, methods, sequences,
procedures, and techniques of construction; safety precautions and
programs incident thereto; and for coordinating the Work of all trades.
4) Engineer is not responsible for the effects of resubmittals or tracking
progress of resubmittals.
4. Delegated Design Informational Submittals:
a. Other provisions of the Contract Documents notwithstanding, Engineer’s review
of delegated design Informational Submittals is limited to only:
1) Verifying the Submittal was furnished as required; and
2) Submittal generally appears complete (except for calculations); and
3) Submittal bears delegated design professional’s approval stamp; or, for
calculations prepared by or for delegated design professional, that such
calculations bear delegated design professional’s seal, signature, and
date; or, for delegated design professional’s reports of visits to the Site,
that such report is legible, and bears delegated design professional’s
signature with date.
b. Engineer receives such Submittals, including delegated design professional’s
calculations, on behalf of Owner, for Owner’s records.
c. Engineer, Owner, and others involved in the Project have the right to rely on delegated
design professional’s approval stamp as meaning that the delegated design professional has
performed and appropriate review of the Submittal and determined it to be complete, in
accordance with delegated design professional’s instruments of service approved by
Engineer, in accordance with delegated design professional’s design intent, and in
accordance with the Contract Documents.
5. Engineer’s Other Comments on Delegated Design Submittals:
a. Despite the limitations of Engineer’s review of Submittals for delegated design
Work, should Engineer become aware of, or reasonably suspect existence of,
potential of associated delegated design Work to adversely affect health,
safety, or welfare of persons, or pose reasonable potential for damage to the
Work, work of other contractors, or adjacent property, Engineer will advise
Contractor in writing of general nature of Engineer’s concern.
b. Such advisory by Engineer, if issued, is rendered in good faith and does not in
any way constitute:
1) Engineer’s review of all aspects of the delegated design.
2) Any sharing by Engineer of any of delegated design professional’s
responsibilities or professional liability.
3) Any responsibility imposed, in any way, on Engineer for any aspect of
the delegated design professional’s services or design, beyond the
limited purposes of Engineer’s review as set forth in the Contract
Documents.
c. Contractor and its Subcontractors and Suppliers, including delegated design
professionals, shall immediately investigate Engineer’s concern indicated in
such advisory and remedy as necessary and required.
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d. Neither Engineer nor Owner, nor their respective consultants and
subcontractors, is obligated to review any Submittal for delegated design Work
beyond the limited review required by the Contract Documents. No such
advisory, if issued, entitles Contractor, Subcontractor, or Supplier, including
delegated design professionals, to rely on such advisory or to assume that any
further such reviews or written or oral advisories are forthcoming.
1.7 RESPONSIBILITIES OF DELEGATED DESIGN PROFESSIONALS
A. Standard of Care:
1. Unless a higher standard of care is established by the Division 02-49 Specifications
section where the associated delegated design Work is required, the delegated design
services shall comply with the following standard of care:
2. Except as provided in the paragraph immediately above this, the standard of care for
all delegated design professional services and related services performed or furnished
by delegated design professionals for the Project will be the care and skill ordinarily
used by members of the subject profession practicing under similar circumstances at
the same time and in the same locality.
B. Responsibilities of delegated design professionals employed on the Work include, but are
not necessarily limited to, the following, unless specifically indicated otherwise in the
associated elements of the Contract Documents where the delegated design is required:
1. Ethical Conduct and Professionalism: Comply with Laws and Regulations and
applicable standards and guidelines relevant design professional organizations for
ethical conduct and professional practice.
2. Comply with Laws and Regulations and relevant design standards applicable to the
subject delegated design Work.
3. Performance and Design Criteria Indicated in the Contract Documents and Other
Information:
a. Review performance and design criteria, indicated in the Contract Documents,
that the delegated design Work must satisfy.
b. Prepare written requests for interpretations or clarifications of performance or
design criteria.
c. Review existing information about the Site that constitutes Technical Data (if
any, applicable to the subject delegated design Work), as indicated in the
Supplementary Conditions.
4. Pre-Design Conference: Actively participate in the pre-design conference, when
required, for the subject delegated design Work.
5. Site Information and Investigations: With Contractor, obtaining all other necessary
dimensions, field information, and other information necessary for preparing
delegated design Submittals.
6. Design and Other Professional Services: Personally perform and prepare, or actively
exercise direct, personal, supervisory control over others performing or preparing:
a. Necessary design professional evaluations of conditions, materials, and
equipment.
b. Prepare the instruments of service Submittals and calculations Submittal for the
subject delegated design Work, where required by the associated Division 02-
49 Specifications and other, associated Contract Documents.
c. Assist Contractor with applying for and obtaining permits and approvals (not
previously obtained by Owner or those for whom Owner is responsible)
necessary for the delegated design Work.
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d. Review and approve or take other appropriate action on Shop Drawings (unless
such Shop Drawings are sealed and signed by delegated design professional),
product data, Samples, and testing plans, and other Submittals associated with
the delegated design Work.
e. Prep modifications of the delegated design instruments of service as necessary.
7. Sealing and Signing:
a. Seal, sign, and indicate date of sealing and signing, on all of the following when
such Submittals are required by the Division 02-49 Specifications where the
delegated design Work is required:
1) Instruments of service Submittals, including certification of compliance
required.
2) Calculations.
3) Modifications to the delegated design.
4) Other documents required to be sealed and signed by Laws or
Regulations or the Contract Documents.
b. Sealing and signing documents in accordance with Laws and Regulations and
the Contract Documents, prior to submittal (through Contractor) to Engineer,
and for submittal to authorities having jurisdiction to obtain necessary permits
and approvals.
8. Certification of Compliance by Delegated Design Professional:
a. Through Contractor, submit to Engineer, delegated design professional’s
written certification indicating:
1) General Information; (1) Project name and designation, (2) Contractor
name and Contract designation, (3) Subcontractor or Supplier name
(when applicable), (4) full name of delegated design professional’s
business entity under which the delegated design services were
performed, (5) full name and license number of the individual sealing
and signing the subject delegated design Work, (6) specific elements of
delegated design Work to which the certification applies, and (7)
delegated design professional’s seal, signature, and date of signature.
2) Explicit certification that the subject delegated design complies with:
a) All applicable performance and design criteria indicated in the
Contract Documents. Expressly indicate on certification of
compliance the specific performance and design criteria used in
the delegated design, and reaction forces of the delegated design
imparted to other Work and existing construction.
3) Applicable design standards commonly applicable to such types of
construction. Expressly indicate such design standards on the
certification of compliance.
9. Approvals of Other Delegated Design Submittals:
a. Review and taking appropriate action on Submittals for delegated designs:
b. Such reviews and approvals or other appropriate action shall be to ascertain
compliance with:
1) Delegated design professional’s design intent.
2) Delegated design professional’s instruments of service and calculations.
3) Associated requirements of the Contract Documents.
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c. Delegated design professional’s review stamp or facsimile thereof, review
action or disposition concerning the associated Submittal for the delegated
design, date of review, and name of person performing the review shall be
clearly legible on the associated Submittals (except for delegated design
professional’s own instruments of service Submittals, calculations, and reports
of delegated design professional’s visits to the Site). Prominently display
delegated design professional’s Submittal review stamp or facsimile thereof on:
(1) each sheet of Shop Drawings, (2) each major section of product data
Submittals, (3) each Sample, (4) each testing plan, and (5) each other
Submittal associated with the delegated design for which such review stamp is
required.
d. Do not apply delegated design professional’s Submittal review stamp and
comments, if any, over other text, tables, or graphics.
e. Where review stamp or facsimile thereof is required, submit to Engineer only
those Submittals for delegated design Work that bear delegated design
professional’s explicit approval of the Submittal.
10. Respond promptly to requests for interpretation or clarification on delegated design
professional’s instruments of service and other Submittals for the delegated design
Work.
11. Progress and Quality of Construction of Delegated Design Work:
a. Where appropriate for the subject delegated design Work, periodically visit the
Site at appropriate intervals to observe the progress and quality of the subject
delegated design Work.
b. Where delegated design professional does not visit the Site during construction,
keep informed of the progress and quality of the subject delegated design
Work via discussions with Contractor, Subcontractor, and Suppliers, via
photographic documentation, and other means acceptable to delegated design
professional.
c. Advise Contractor in writing when the subject delegated design Work is not in
accordance with the delegated design professional’s instruments of service
(approved by Engineer) and related Submittals approved by delegated design
professional.
d. Furnish copy of delegated design professional’s written report of each visit to
the Site to the Engineer.
12. Modifications to Design:
a. Design appropriate modifications to the delegated design Work, including
preparing new or revised certifications, reports, design drawings, sketches,
design specifications, and calculations, as appropriate.
b. Such instruments of service and calculations shall be submitted to Engineer
through Contractor to same extent original instruments of service Submittals
and calculations, if any, where required by the Contract Documents for the
subject delegated design Work.
13. Other services, as mutually agreed upon by delegated design professional and its
client, or as required elsewhere in the Contract Documents.
PART 2 - PRODUCTS - (NOT USED)
PART 3 - EXECUTION - (NOT USED)
END OF SECTION
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SECTION 0140 00
QUALITY REQUIREMENTS
GENERAL
1.1SUMMARY
This Section includes administrative and procedural requirements for quality assurance and
quality control.
Testing and inspecting services are required to verify compliance with requirements
specified or indicated. These services to not relieve CONTRACTOR of responsibilityfor
compliance with the Contract Document requirements.
Specific quality-assurance and -control requirements for individual construction
activities are specified in the Sections that specify those activities. Requirements in
those Sections may also cover production of standard products.
Specified tests, inspections, and related actions do not limit CONTRACTOR’S other
quality-assurance and -control procedures that facilitate compliance with the Contract
Document requirements.
Provisionsof this Section do not limit requirements for CONTRACTORto provide
quality-assurance and -control services required by ENGINEER, OWNER, or authorities
having jurisdiction.
1.2RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division1 Specification Sections, apply to this Section.
Related Sections include the following:
Section 013300 “Submittal Procedures.”
All other Contract Documentsections for specific test and inspection requirements.
1.3DEFINITIONS
Quality-Assurance Services: Activities, actions, and procedures performed before and during
execution of the Work to guard against defects and deficiencies and substantiate that
proposed construction will comply with requirements.
Quality-Control Services: Tests, inspections, procedures, and related actions during and
after execution of the Work to evaluate that actual products incorporated into the Work and
completed construction comply with requirements. Services do not include contract
enforcement activities performed by ENGINEER.
Mockups: Full-size, physical assemblies that are constructed on-site. Mockups are used to
verify selections made under sample submittals, to demonstrate aesthetic effects and, where
indicated, qualities of materials and execution, and to review construction, coordination,
testing, or operation; they are not Samples. Approved mockups establish the standard by
which the Work will be judged.
Laboratory Mockups: Full-size, physical assemblies that are constructed at testing facility to
verify performance characteristics.
Product Testing: Tests and inspections that are performed by a Nationally Recognized
Testing Laboratory (NRTL), a National Voluntary Laboratory Accreditation Program (NVLAP),
or a testing agency qualified to conduct product testing and acceptable to authorities having
jurisdiction, to establish product performance and compliance with industry standards.
Source Quality-Control Testing: Tests and inspections that are performed at the source, i.e.,
plant, mill, factory, or shop.
Field Quality-Control Testing: Tests and inspections that are performed on-site for
installation of the Work and for completed Work.
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Independent Testing Agency: An entity engaged by separate contractwith the OWNERto
perform specific tests, inspections, or both. The terms Independent Testing Laboratory and
Independent Testing Agency shall have equivalent meaning.
Testing Agency: An entity engaged by the CONTRACTORto perform specific tests,
inspections, or both identifiedas the CONTRACTOR’Sresponsibility by the Contract
Documents. Testing Laboratory shall mean the same as Testing Agency.
Installer/Applicator/Erector: CONTRACTORor another entity engaged by CONTRACTORas
an employee, Subcontractor, or Sub-subcontractor, to perform a particular construction
operation, including installation, erection, application, and similar operations.
Using a term such as "carpentry" does not imply that accredited or unionized
individuals of a corresponding generic name, such as “carpenter”, must perform
certain construction activities. It also does not imply that requirements specified
apply exclusively to trades people of the corresponding generic name.
Experienced: When used with an entity, "experienced" means having successfully
completed a minimum of five (5) previous projects similar in size and scope to this Project;
being familiar with special requirements indicated; and having complied with requirements
of authorities having jurisdiction.
1.4CONFLICTING REQUIREMENTS
General: If compliance with two or more standards is specified and the standards establish
different or conflicting requirements for minimum quantities or quality levels, comply with
the most stringent requirement. Refer uncertainties and requirements that are different, but
apparently equal, to ENGINEERfor a decision before proceeding.
Minimum Quantity or Quality Levels: The quantity or quality level shown or specified shall
be the minimum provided or performed. The actual installation may comply exactly with the
minimum quantity or quality specified, or it may exceed the minimum within reasonable
limits. To comply with these requirements, indicated numeric values are minimum or
maximum, as appropriate, for the context of requirements. Refer uncertainties to
ENGINEERfor a decision before proceeding.
1.5SUBMITTALS
Qualification Data: For Testing Agencies specified in Paragraph1.6 "Quality Assurance" to
demonstrate their capabilities and experience. Include proof of qualifications in the form of
a recent report on the inspection of the testing agency by a recognized authority.
1.6QUALITY ASSURANCE
General: Qualifications paragraphs in this Article establish the minimum qualification levels
required; individual Specification Sections specify additional requirements.
Installer Qualifications: A firm or individual experienced in installing, erecting, or assembling
work similar in material, design, and extent to that indicated for this Project, whose work
has resulted in construction with a record of successful in-service performance.
Manufacturer Qualifications: A firm experienced in manufacturing products or systems
similar to those indicated for this Project and with a record of successful in-service
performance, as wellas sufficient production capacity to produce required units.
Fabricator Qualifications: A firm experienced in producing products similar to those
indicated for this Project and with a record of successful in-service performance, as well as
sufficient production capacity to produce required units.
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Professional Engineer Qualifications: A professional engineer who is legally qualified to
practice in jurisdiction where Project is located and who is experienced in providing
engineering services of the kind indicated. Engineering services are defined as those
performed for installations of the system, assembly, or products that are similar to those
indicated for this Project in material, design, and extent.
Testing Agency Qualifications:
Laboratory facilities,including personnel, and equipment, utilized shall meet the
criteria detailed in ASTM E329 “Specification for Agencies Engaged in Construction
Inspection and/or Testing”, ASTM D3666 “Practice for Minimum Requirements for
Agencies Testing and Inspecting Road and Paving Materials,” and ASTM D3740
“Practice for Minimum Requirements for Agencies Engaged in the Testing and/or
Inspection of Soil and Rock as Used in Engineering Design and Construction.”
Testing Agency shall be accredited by the American Association of Laboratory
Accreditation (AALA), National Institute of Standards and Technology (NIST), NVLAP,
the American Association of State Highway and Transportation Officials (AASHTO)), or
other nationally recognized testing laboratory according to 29CFR1910.7.
Comply with additional qualifications specified in individual Sections; and where
required by authorities having jurisdiction, that is acceptable to authorities.
Factory-Authorized Service Representative Qualifications: An authorized representative of
manufacturer who is trained and approved by manufacturer to inspect installation of
manufacturer's products that are similar in material, design, and extent to those indicated
for this Project.
Mockups: If applicable, before installing portions of the Work requiring mockups, build
mockups for each form of construction and finish required to comply with the following
requirements, using materials indicated for the completed Work:
Build mockups in location and of size indicated or, if not indicated, as directed by
ENGINEER.
Notify ENGINEERseven days in advance of dates and times when mockups will be
constructed.
Demonstrate the proposed range of aesthetic effects and workmanship.
Obtain ENGINEER’Sapproval of mockups before starting work, fabrication, or
construction.
Allow seven days for initial review and each re-review of each mockup.
Maintain mockups during construction in an undisturbed condition as a standard for
judging the completed Work.
Demolish and remove mockups when directed, unless otherwise indicated.
1.7QUALITY CONTROL
Owner Responsibilities: The OWNERis required by law to provide quality-control services
using an Independent Testing Agency.The OWNERwill engage a qualified Independent
Testing Agency to perform these services.
Costs for retesting and reinspecting construction that replaces or is necessitated by
work that failed to comply with the Contract Documents will be charged to
CONTRACTOR. A deductiveChange Order will be used to adjust the Contract Sum.
The OWNERshall provide field and laboratory services in connection with verification
surveying, geotechnical analysis and construction materials testing required by
separate contract with an Independent Testing Agency or other consultant. Such
work includes but is not limited to the following:
Testing of concrete mix designs, design of asphalt mixtures, lime stabilization
of subgrade, flowable mix design, and related design parameter
determinations.
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Determination of soil test for classifications of on-site and off-site borrow
materials, soil densities and moisture determination of subgrade and
embankment materials, cement or lime stabilization of subgrade, and other
related testing required during construction.
Weld inspection, coating inspections, torque requirements forsteel erection,
and other non-destructive testing required by the Contract Documents.
Vacuum and pressure testing of pipe lines, manholes, and related work,
including disinfection testing of potable water lines and CCTV of lines directed
by the Contract Documents.
All inspection and testing work not specifically stated to be the CONTRACTOR’S
responsibility.
Verification surveys of final constructed grades, by a Registered Professional
Land Surveyor (RPLS) licensed in the State of Texas, where required by the
Contract Documents.
Where quality-control services are indicated as OWNER’Sresponsibility, the
independent testing agency or other consultant shall be required by contract with the
OWNERto preparecertified written reportsto be submitted in accordance with
Section 01 3300 “Submittal Procedures” for each quality-control service.
Contractor Responsibilities: Only such tests and inspections that are explicitly assigned to
the CONTRACTORshall be the CONTRACTOR’Sresponsibility. Unless otherwise indicated,
the OWNERshall provide both the quality-control services specified and those required by
authorities having jurisdiction. Perform the following quality-control services.
Where services are specifically indicated as CONTRACTOR’Sresponsibility, engage a
qualified testing agency to perform these quality-control services.
CONTRACTORshall not employ same entity engaged by OWNER, unless agreed
to in writing by OWNER.
Notify Testing Agencies at least 24 hours in advance of time when Work that requires
testing or inspecting will be performed.
Where quality-control services are specifically indicated as CONTRACTOR’S
responsibility, the selected Testing Agencyshall preparecertified written reports to be
submitted by the CONTRACTORin accordance withSection 013300 “Submittal
Procedures”for each quality-control service.
Testing and inspecting desired by CONTRACTORand not required by the Contract
Documents are CONTRACTOR’S responsibility.
Submit additional copies of each written report directlyto authorities having
jurisdiction, when they so direct.
The CONTRACTOR shall provide construction surveying required to construct the
improvements as depicted on the plans.
Manufacturer's Field Services: Where indicated, engage a factory-authorized service
representative to inspect field-assembled components and equipment installation, including
service connections. Report results in writing as specified inSection013300“Submittal
Procedures.”
Retesting/Reinspecting: Regardless of whether original tests or inspections were
CONTRACTOR’Sresponsibility, provide quality-control services, including retesting and
reinspecting, for construction ofreplaced Work that failed to comply with the Contract
Documents. Should laboratory services provided by the OWNERunder Paragraph 1.7 A of
this Section indicate the work does not meet Contract Document requirements,the cost of
additional testing or surveying shall be paid by the CONTRACTORby deductive Change
Order to the Contract Amount. The testing or surveying services required shall be
performed by the Independent Testing Agency or other consultant under separate contract
with the OWNER.
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Independent Testing Agency Responsibilities: Cooperate with ENGINEERand CONTRACTOR
in performanceof duties. Provide qualified personnel to perform required tests and
inspections. The Independent Testing Agency shall:
Notify ENGINEERand CONTRACTORpromptly of irregularities or deficiencies
observed in the Work during performance of its services.
Determine the location from which test samples will be taken and in which in-situ
tests are conducted.
Conduct and interpret tests and inspections and state in each report whether tested
and inspected work complies with or deviates from requirements.
Submit a certified written report, distribution as indicated, of each test, inspection,
and similar quality-control service in accordance withSection 013300 “Submittal
Procedures” for each quality-control service.
Not release, revoke, alter, or increase the Contract Document requirements or
approve or accept any portion of the Work.
Not perform any duties of CONTRACTOR.
Associated Services: CONTRACTORshall cooperate with all agencies, whether under
contract with the OWNERor CONTRACTOR,performing required tests, inspections, and
similar quality-control services, and provide reasonable auxiliary services as requested.
Notify all agencies, whether under contractwith the OWNERor CONTRACTOR, sufficiently in
advance of operations to permit assignment of personnel. Provide the following:
Access to the Work.
Incidental labor and facilities necessary to facilitate tests and inspections.
Adequate quantities of representative samples of materials that require testing and
inspecting. Assist agency in obtaining samples.
Facilities for storage and field curing of test samples.
Delivery of samples to testing agencies as applicable.
Preliminary design mix proposed for use for material mixes that require control by
testing agency.
Security and protection for samples andfor testing and inspecting equipment at
Project site.
Coordination: CONTRACTORshall coordinate sequence of activities to accommodate
required quality-assurance and quality-control services with a minimum of delay and to
avoid necessity of removing and replacing construction to accommodate testing and
inspecting.
Schedule times for tests, inspections, obtaining samples, and similar activities.
PRODUCTS (NOT USED)
EXECUTION
3.1TEST AND INSPECTION LOG
Prepare a record of tests and inspections. Include the following:
Date test or inspection was conducted.
Description of the Work tested or inspected.
Date test or inspection results were transmitted to ENGINEER.
Identification of testing agency or special inspector conducting test or inspection.
Maintain log at Project site. Post changes and modifications as they occur. Provide access
to test and inspection log for ENGINEER’Sreference during normal working hours.
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3.2REPAIR AND PROTECTION
General: On completion of testing, inspecting, sample taking, and similar services, repair
damaged construction and restore substrates and finishes.
Provide materials and comply with installation requirements specified in other
Specification Sections. Restore patched areas and extend restoration into adjoining
areas with durable seams that are as invisible as possible.
Protect construction exposed by or for quality-control service activities.
Repair and protection are CONTRACTOR’Sresponsibility, regardless of the assignment of
responsibility for quality-control services.
END OF SECTION
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SECTION 014200
REFERENCES
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division1 Specification Sections, apply to this Section.
1.2DEFINITIONS
General: Basic Contract definitions are included in the Conditions of the Contract.
"Approved": When usedto convey ENGINEER’Saction on Contractor's submittals,
applications, and requests, "approved" is limited to ENGINEER’S duties and responsibilities
as stated in the Conditions of the Contract.
"Directed": A command or instruction by ENGINEER. Other terms including "requested,"
"authorized," "selected," "required," and "permitted" have the same meaning as "directed."
"Indicated": Requirements expressed by graphic representations or in written form on
Drawings, in Specifications, and in other Contract Documents. Other terms including
"shown," "noted," "scheduled," and "specified" have the same meaning as "indicated."
"Regulations": Laws, ordinances, statutes, and lawful orders issued by authorities having
jurisdiction, and rules, conventions, and agreements within the construction industry that
control performance of the Work.
"Furnish": Supply and deliver to Project site, ready for unloading, unpacking, assembly,
installation, and similar operations.
"Install": Operations at Project site including unloading, temporarily storing, unpacking,
assembling, erecting, placing, anchoring, applying, working to dimension, finishing, curing,
protecting, cleaning, and similar operations.
"Provide": Furnish and install, complete and ready for the intended use.
"Project Site": Space available for performing construction activities. The extent of Project
site is shown on Drawings and may or may not be identical with the description of the land
on which Project is to be built.
1.3INDUSTRY STANDARDS
Applicability of Standards: Unless the Contract Documents include more stringent
requirements, applicable construction industry standards have the same force and effect as
if bound or copied directly into the Contract Documents to the extent referenced. Such
standards are made a part of the Contract Documents by reference.
Publication Dates: Comply with standards in effect as of date of the Contract Documents
unless otherwise indicated.
Copies of Standards: Each entity engaged in construction on Project should be familiar with
industry standards applicable to its construction activity. Copies of applicable standards are
not bound with the Contract Documents.
Where copies of standards are needed to perform a required construction activity, obtain
copies directly from publication source.
Abbreviations and Acronyms for Standards and Regulations: Where abbreviations and
acronyms are used in Specifications or other Contract Documents, they shall mean the
recognized name of the organizations responsible for the standards and regulations in the
following list.
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ADAAGAmericans with Disabilities Act (ADA)
Architectural Barriers Act (ABA)
CFRCode of Federal Regulations
DODDepartment of Defense Military Specifications and Standards
DSCCDefense Supply Center Columbus (See FS)
FED-STDFederal Standard (See FS)
FSFederal Specification
FTMSFederal Test Method Standard (See FS)
MIL(See MILSPEC)
MIL-STD(See MILSPEC)
MILSPECMilitary Specification and Standards
UFASUniform Federal Accessibility Standards
TASTexas Accessibility Standards
TDLRTexas Department of Licensing and Regulations
1.4ABBREVIATIONS AND ACRONYMS
Industry Organizations: Where abbreviations and acronyms are used in Specifications or
other Contract Documents, they shall mean the recognized name of the entities in the
following list.
AAAluminum Association, Inc. (The)
AAADMAmerican Association of Automatic Door Manufacturers
AAMAAmerican Architectural Manufacturers Association
AASHTOAmerican Association of State Highway and Transportation Officials
ABMAAmerican Bearing Manufacturers Association
ACIACI International (American Concrete Institute)
ACPAAmerican Concrete Pipe Association
AEICAssociation of Edison Illuminating Companies, Inc. (The)
AGAAmerican Gas Association
AGCAssociated General Contractors of America (The)
AIAsphalt Institute
AIAAmerican Institute of Architects (The)
AISCAmerican Institute of Steel Construction
AISIAmerican Iron and Steel Institute
AITCAmerican Institute of Timber Construction
ALCAAssociated Landscape Contractors of America
(Now PLANET -Professional Landcare Network)
ALSCAmerican Lumber Standard Committee, Incorporated
AMCAAir Movement & Control Association International, Inc.
ANSIAmerican National Standards Institute
APAArchitectural Precast Association
APIAmerican Petroleum Institute
ARIAir-Conditioning & Refrigeration Institute
ARMAAsphalt Roofing Manufacturers Association
ASCEAmerican Society of Civil Engineers
ASHRAEAmerican Society of Heating, Refrigerating and Air-Conditioning
Engineers
ASMEASME International
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ASSE American Society of Sanitary Engineering
ASTM ASTM International
(American Society for Testing and Materials International)
AWI Architectural Woodwork Institute
AWPA American Wood-Preservers' Association
AWS American Welding Society
AWWA American Water Works Association
BHMA Builders Hardware Manufacturers Association
BIA Brick Industry Association (The)
CGA Compressed Gas Association
CISPI Cast Iron Soil Pipe Institute
CLFMI Chain Link Fence Manufacturers Institute
CPA Composite Panel Association
CPPA Corrugated Polyethylene Pipe Association
CRSI Concrete Reinforcing Steel Institute
CSI Cast Stone Institute
CSI Construction Specifications Institute (The)
DHI Door and Hardware Institute
DMS Departmental Material Specifications, TxDOT
EIA Electronic Industries Alliance
EJCDC Engineers Joint Contract Documents Committee
EJMA Expansion Joint Manufacturers Association, Inc.
FMG FM Global (Formerly: FM - Factory Mutual System)
FMRC Factory Mutual Research (Now FMG)
HI Hydraulic Institute
HMMA Hollow Metal Manufacturers Association (Part of NAAMM)
HPVA Hardwood Plywood & Veneer Association
ICEA Insulated Cable Engineers Association, Inc.
IEEE Institute of Electrical and Electronics Engineers, Inc. (The)
IESNA Illuminating Engineering Society of North America
IEST Institute of Environmental Sciences and Technology
IGCC Insulating Glass Certification Council
IGMA Insulating Glass Manufacturers Alliance
ISO International Organization of Standardization
LPI Lightning Protection Institute
MBMA Metal Building Manufacturers Association
MFMA Metal Framing Manufacturers Association
MHIA Material Handling Industry of America
MSS Manufacturers Standardization Society of The Valve and Fittings
Industry Inc.
NAAMM National Association of Architectural Metal Manufacturers
NACE NACE International
(National Association of Corrosion Engineers International)
NRCA National Roofing Contractors Association
NECA National Electrical Contractors Association
NEMA National Electrical Manufacturers Association
NETA InterNational Electrical Testing Association
NFPA NFPA (National Fire Protection Association)
NGA National Glass Association
NHLA National Hardwood Lumber Association
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NSFNSF International (National Sanitation Foundation International)
NWWDANational Wood Window and Door Association (Now WDMA)
PCIPrecast/Prestressed Concrete Institute
PDCAPainting & Decorating Contractors of America
PDIPlumbing & Drainage Institute
PGIPVC Geomembrane Institute
PLANETProfessional Landcare Network
(Formerly: ACLA -Associated Landscape Contractors of America)
PTIPost-Tensioning Institute
RCSCResearch Council on Structural Connections
SAESAE International
SDISteel Deck Institute
SDISteel Door Institute
SIGMASealed Insulating Glass Manufacturers Association (Now IGMA)
SJISteel Joist Institute
SMACNASheet Metal and Air Conditioning Contractors' National Association
SSINASpecialty Steel Industry of North America
SSPCSSPC: The Society for Protective Coatings
STISteel Tank Institute
ULUnderwriters Laboratories Inc.
UNIUni-Bell PVC Pipe Association
WASTECWaste Equipment Technology Association
WDMAWindow & Door Manufacturers Association (Formerly: NWWDA -
National Wood Window and Door Association)
Code Agencies: Where abbreviations and acronyms are used in Specifications or other
Contract Documents, they shall mean the recognized name of the entities in the following
list.
BOCABOCA International, Inc. (See ICC)
IAPMOInternational Association of Plumbing and Mechanical Officials
ICBOInternational Conference of Building Officials (See ICC)
ICBO ESICBO Evaluation Service, Inc. (See ICC-ES)
ICCInternational Code Council
ICC-ESICC Evaluation Service, Inc.
SBCCISouthern Building Code Congress International, Inc. (See ICC)
Federal Government Agencies: Where abbreviations and acronyms are used in
Specifications or other Contract Documents, they shall mean the recognized name of the
entities in the following list.
CEArmy Corps of Engineers
CPSCConsumer Product Safety Commission
DOCDepartment of Commerce
DODDepartment of Defense
DOEDepartment of Energy
EPAEnvironmental Protection Agency
FAAFederal Aviation Administration
FCCFederal Communications Commission
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FDAFood and Drug Administration
GSAGeneral Services Administration
HUDDepartment of Housing and Urban Development
NCHRPNational Cooperative Highway Research Program (See TRB)
NISTNational Institute of Standards and Technology
OSHAOccupational Safety & Health Administration
PBSPublic Building Service (See GSA)
PHSOffice of Public Health and Science
RUSRural Utilities Service (See USDA)
SDState Department
TRBTransportation Research Board
USDADepartment of Agriculture
USPSPostal Service
State Government and Regional Agencies: Where abbreviations and acronyms are used in
Specifications or other Contract Documents, they shall mean the recognized name of the
entities in the following list. Names, telephone numbers, and Web sites are subject to
change and are believed to be accurate and up-to-date as of the date of the Contract
Documents.
TCEQTexas Commission on Environmental Quality
TWDBTexas Water Development Board
TxDOTTexas Department of Transportation
PRODUCTS (NOT USED)
EXECUTION (NOT USED)
END OF SECTION
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SECTION 0143 33
MANUFACTURER’S FIELDSERVICES
GENERAL
1.1SUMMARY
This Section includes the requirements for the qualifications, services, training, installation
assistance, and related Work required for manufacturers’ services.
1.2REFERENCES
Drawingsand general provisions of the Contract, including General and Supplementary
Conditions and other Division1Specification Sections, apply to this Section.
Related Sections include the following:
Section 01 75 25“Equipment Testing and Startup.”
Section 017823“Operation and Maintenance Data” for requirements for furnishing
operation and maintenance information and materials.
Section 01 79 00“Demonstration and Training”
All other Contract Documentsfor additional requirements.
Definitions
Person-Day: One person for 8 hours within regular CONTRACTOR working hours.
1.3SUBMITTALS
Training Schedule: Submit not less than 21 days prior to start of equipment installation.
Lesson Plan: Submit proposed lesson plan not less than 21 days prior to schedule training
session.
1.4QUALITY ASSURANCE
Authorized representative of the manufacturer, factory trained, and experienced in the
technical applications, operation, and maintenance of respective equipment, subsystem, or
system, with full authority by theequipment manufacturer to issue the certifications require
of equipment manufacturer. Additional qualifications may be specified in the individual
Sections.
Representative will be subject to acceptance by ENGINEER and OWNER. No substitute
representative will be allowed unless prior written approval has been given.
1.5PRODUCTS (NOT USED)
EXECUTION
2.1MANUFACTURERS’ SERVICES
Furnish minimum manufacturers’ services, when required by the Contract Documents, to
comply with the requirements of this Section.
Where timeis necessary in excess of that stated in the Section for manufacturers’ services,
or when a minimum time is not specified, the time required to perform the specified services
shall be considered incidental.
Schedule manufacturers’ services to avoid conflict with other onsite testing or other
manufacturers’ onsite services.
Determine, before scheduling manufacturers’ services that all conditions necessary to allow
successful completion of the services have been complied with.
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Only those days of service approved by ENGINEER will be credited to fulfill the specified
minimum service.
When specified by the Contract Documents, manufacturer’s onsite services shall include:
Assistance during product (system, subsystem, or component) installation to include
observation, guidance, and instruction of CONTRACTOR’S personnel during the
assembly, erection, installation or application Work.
Inspection, checking, and adjustments as required for product (system, subsystem, or
component) to function as warranted by manufacturer and required to provide
Manufacturer’s Certificate of Installation.
Provide on a daily basis copies of manufacturer’s representative field notes and data
to ENGINEER.
Visiting site as required to correct problems and until installation and operation are
acceptable to ENGINEER.
Resolution of assemble or installation problems attributable to, or associated with,
respective manufacturer’s products and systems.
Assistance during functional and performance testing, facility start-up, evaluation, and
commissioning.
Training of OWNER’S personnel in the operation and maintenance of the product as
required.
Additional requirements may be specified in applicable Section(s).
2.2MANUFACTURER’S CERIFICATE OF COMPLIANCE
When specified in the Contract Documents, provide aManufacturer’s Certificate of
Compliance, completed and signed by the entity supplying the product, material, or service
prior to shipment. A copy of this form is attached to this Section.
ENGINEER may permit use of certain products, materials, or service prior to sampling and
testing if accompanied by an accepted Certificate of Compliance.
The Certificate shall certify the product, material, or service complies with the Contract
Documents. Attach supporting documentation as appropriate. This information may reflect
previous test results on the product, material, or services.
2.3MANUFACTURER’S CERTIFICATE OF INSTALLATION
When specified in the Contract Documents, provide a Manufacturer’s Certificate of Proper
Installation, completed and signed by the manufacturer’s representative. A copy of this form
is attached to this Section.
The Certificate shall certify the signing party is a dully-authorized representative of the
manufacturer, is empowered by the manufacturer to inspect, approve the installation,
operate their equipment, and make recommendations required to ensure the equipment
installation is complete and operational.
2.4EQUIPMENT TESTING AND STARTUP
Provide manufacturers’ representative to assist CONTRACTOR for the specified product
(system, subsystem, and component) on accordance with Section 01 75 25“Equipment
Testing and Startup.”
2.5TRAINING
Provide manufacturers’ representative for detailed classroom and hands-on training to
OWNER’S personnel on the operation and maintenance of specified product (system,
subsystem, and component). Refer to Section 01 79 00“Demonstration and Training” for
additionalrequirements.
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Furnish trained, articulate personnel to coordinate and expedite training, to be present
during training coordination meetings with OWNER and familiar with required operation and
maintenance information submitted in accordance with Section 01 78 23“Operation and
Maintenance Data.”
Furnish training materials, which will be retained by the trainee.
2.6SUPPLEMENTS
The following forms located after“END OF SECTION” are part of this Section:
Form: Manufacturer’s Certificate of Compliance.
Form: Manufacturer’s Certificate of Installation.
END OF SECTION
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MANUFACTURER’S CERTIFICATE OF COMPLIANCE
OWNER:
PRODUCT, MATERIAL OR SERVICE:
PROJECT NAME:
Comments:
I hereby certify that the above-referenced product, material, or service called for by the Contract for the
named Project has been furnished in accordance with all applicable requirements. I further certify that
the product, material, or service is of the quality specified and conform in all respects with the Contract
Documents, and of the quantity shown.
Date of Execution:
Manufacturer:
Manufacturer's Authorized Agent (Print):
(Authorized Signature)
Attachments: Add comments on separate sheets as applicable.
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MANUFACTURER’S CERTIFICATE OF PROPER INSTALLATION
Owner: Serial No.:
Tag No.: System:
Project No.: Spec. Section:
I hereby certify the above referenced equipment/system has been:
(Check Applicable)
Installed in accordance with manufacturer’s recommendations.
Inspected, checked, and adjusted.
Serviced with proper lubricants.
Electrical and mechanical connections meet quality and safety requirements.
All applicable safety equipment has been properly installed.
Functional test completed.
System has been performance tested, and meets or exceeds specified performance
requirements. (When complete system furnished by single manufacturer)
Date of Execution:
Manufacturer:
Manufacturer's Authorized Agent (Print):
(Authorized Signature)
Attachments: Add comments on separate sheets as applicable.
END OF SECTION
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SECTION 016000
PRODUCT REQUIREMENTS
GENERAL
1.1SUMMARY
This Section includes administrative and procedural requirements for selection of products
for use in Project; product delivery, storage, and handling; manufacturers' standard
warranties on products; special warranties; product substitutions; and comparable products.
Related Sections include the following:
Section 014200 "References" for applicable industry standards for products
specified.
Section 017700 "Closeout Procedures" for submitting warranties for Contract
closeout.
Section 01 78 36 “Warranties.”
All other Contract Documentsfor specific requirements for warranties on products and
installations specified to be warranted.
1.2REFERENCES
Preselection Drawings and general provisions of the Contract, including Preselection Special
Conditions and Division 1 Specification Sections, apply to this Section.
Definitions
Products: Items purchased for incorporating into the Work, whether purchased for
Project or taken from previously purchased stock. The term "product" includes the
terms "material," "equipment," "system," and terms of similar intent.
Named Products: Items identified by manufacturer's product name, including
make or model number or other designation shown or listed in manufacturer's
published product literature, which is current as of date of the Contract
Documents.
New Products: Items that have not previously been incorporated into another
project or facility,except that products consisting of recycled-content materials
are allowed, unless explicitly stated otherwise. Products salvaged or recycled
from other projects are not considered new products.
Comparable Product: Product that is demonstrated and approved through
submittal process, or where indicated as a product substitution, to have the
indicated qualities related to type, function, dimension, in-service performance,
physical properties, appearance, and other characteristics that equal or exceed
those of specified product.
Substitutions: Changes in products, materials, equipment, and methods of
construction from those required by the Contract Documents and proposed by
Contractor.
Basis-of-Design Product Specification: Where a specific manufacturer's product is
named and accompanied by the words "basis of design," including make or model
number or other designation, to establish the significant qualities related to type,
function, dimension, in-service performance, physical properties, appearance, and
other characteristics for purposes of evaluatingcomparable products of other named
manufacturers.
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1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Material and Equipment List. Within 60 days after Notice to Proceed, submit a complete list
of major products proposed for the Project, with the name of the manufacturer and the
installing entity.
Substitution Requests: Submit three copies of each request for consideration. Identify
product or fabrication or installation method to be replaced. Include Specification Section
number and title; Drawing numbersand titles; sufficient information for review by
ENGINEER; CONTRACTOR’S certification that proposed substitution complies with
requirements in the Contract Documents and is appropriate for applications indicated; and
CONTRACTOR’S waiver of rights to additional payment or time that may subsequently
become necessary because of failure of proposed substitution to produce indicated results.
Substitution Request Form: Use form provided at end of Section.
Documentation: Show compliance with requirements for substitutions and the
following, as applicable:
Statement indicating why specified material or product cannot be provided.
Coordination information, including a list of changes or modifications needed to
other parts of the Work and to construction performed by OWNERand
separate contractors, which will be necessary to accommodate proposed
substitution.
Detailed comparison of significant qualities of proposed substitution with those
of the Work specified. Significant qualities may include attributes such as
performance, weight, size, durability, visual effect, and specific features and
requirements indicated.
Product Data, including drawings and descriptions of products and fabrication
and installation procedures.
Samples, where applicable or requested.
List of similar installations for completed projects with project names and
addresses and names and addresses of architects, engineers, and owners.
Material test reports from a qualified testing agency indicating and interpreting
test results for compliance withrequirements indicated.
Research/evaluation reports evidencing compliance with building code in effect
for Project, from a model code organization acceptable to authorities having
jurisdiction.
Cost information, including a proposal of change, if any, in the Contract Sum.
CONTRACTOR’S certification that proposed substitution complies with
requirements in the Contract Documents and is appropriate for applications
indicated.
CONTRACTOR’S waiver of rights to additional payment or time that may
subsequently become necessary because of failure of proposed substitution to
produce indicated results.
ENGINEER’S Action: If necessary, ENGINEER will request additional information or
documentation for evaluation within 7 days of receipt of a request for substitution.
ENGINEER will notify CONTRACTOR of acceptance or rejection of proposed
substitution within 15 days of receipt of request, or 7 days of receipt of additional
information or documentation, whichever is later.
Form of Acceptance: Change Order or Field Order.
Use product specified if ENGINEER cannot make a decision on use of a
proposed substitution within time allocated.
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Comparable Product Requests: Submit three copies of each request for consideration.
Identify product or fabrication or installation method to be replaced. Include Specification
Section number and title and Drawing numbers and titles.
ENGINEER’S Action: If necessary, ENGINEER will request additional information or
documentation for evaluation within one week of receipt ofa comparable product
request. ENGINEER will notify CONTRACTORof approval or rejection of proposed
comparable product request within 15 days of receipt of request, or 7 days of receipt
of additional information or documentation, whichever is later.
Form of Approval: As specified in Section 01 33 00 “SubmittalProcedure."
Use product specified if ENGINEER cannot make a decision on use of a
comparable product request within time allocated.
Basis-of-Design Product Specification Submittal: Comply with requirements in
Section013300 "SubmittalProcedures." Show compliance with requirements.
1.5QUALITY ASSURANCE
Compatibility of Options: If CONTRACTOR is given option of selecting between two or more
products for use on Project, product selected shall be compatible with products previously
selected, even if previously selected products were also options.
Design Requirements: Where CONTRACTOR design is specified; design of installation,
systems, equipment, and components, including supports and anchorage, shallbe in with
provisions of International Building Code by International Code Council. Refer to the
drawings for required design load criteria.
Environmental Requirements: Provide products suitable for installation and operation under
rated conditions at 650feet above sea level. Products installed outdoors or in unheated
enclosures shall be capable of continuous operation within an ambient temperature range of
10°F to 110°F.
Product installations are defined as equipment furnished for an individual facility installed as
part of a single project. Multiple equipment items installed as part of the same project shall
not be considered multiple installations. Multiple equipment items installed at the same
facility at different times as part of different projectscan be considered multiple installations.
1.6PRODUCT DELIVERY, STORAGE, AND HANDLING
Deliver, store, and handle products using means and methods that will prevent damage,
deterioration, and loss, including theft. Comply with manufacturer's written instructions.
Delivery and Handling:
Schedule delivery to minimize long-term storage at Project site and to prevent
overcrowding of construction spaces.
Coordinate delivery with installation time to ensure minimum holding time for items
that are flammable, hazardous, easily damaged, or sensitive to deterioration, theft,
and other losses.
Deliver products to Project site in an undamaged condition in manufacturer's original
sealed container or other packaging system, complete with labels and instructions for
handling,storing, unpacking, protecting, and installing.
Inspect products on delivery to ensure compliance with the Contract Documents and
to ensure that products are undamaged and properly protected.
Storage:
Store products to allow for inspection and measurementof quantity or counting of
units.
Store materials in a manner that will not endanger Project structure.
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Store products that are subject to damage by the elements, under cover in a
weathertight enclosure above ground, with ventilation adequate to prevent
condensation.
Store cementitious products and materials on elevated platforms.
Store foam plastic from exposure to sunlight, except to extent necessary for period of
installation and concealment.
Comply with product manufacturer's written instructions for temperature, humidity,
ventilation, and weather-protection requirements for storage.
Protect stored products from damage and liquids from freezing.
Off-site storage of materials and equipment shall be the sole responsibility of the
CONTRACTOR.
1.7SITE CONDITIONS
The equipment, sizes, materials, and arrangements described in this sectionare based on
recommendations by equipment suppliersand shall be considered minimum limits of
acceptability.The PRESELECTED EQUIPMENT SUPPLIER shall be responsible for design,
arrangement, and performance of all equipment supplied under this section.
Environmental Conditions:
All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipal wastewater treatment plants.
All equipment shall be designed and capableof operation outdoors at ambient
temperatures of 10°F to 110°F.
Equipment shall be compatible with heat tracing and insulation, which will be
furnished and installed by the CONTRACTOR. Equipment SUPPLIERsshall design
piping systems with ample clearances and material compatibility to accept required
heat tracing and insulation. If additional freeze protection beyond heat tracing and
insulation is required it shall be furnished by the Equipment SUPPLIER. Equipment
SUPPLIERs and PRESELECECTED EQUIPMENT SUPPLIERsshall coordinate with the
CONTRACTOR to provide directionon where heat tracing is required, and shall verify
that the CONTRACTOR has provided adequate heat tracing and insulation during
startup activities.
1.8PRODUCT WARRANTIES
Warranties specified in other Sections shall be in addition to, and run concurrent with, other
warranties required by the Contract Documents. Manufacturer's disclaimers and limitations
on product warranties do not relieve Contractor of obligations under requirements of the
Contract Documents.
Manufacturer's Warranty: Preprinted written warranty published by individual
manufacturer for a particular product and specifically endorsed by manufacturer to
OWNER.
Special Warranty: Written warranty required by or incorporated into the Contract
Documents, either to extend time limit provided by manufacturer's warranty or to
provide more rights for OWNER.
Refer to Section 01 78 36 “Warranties” for additional requirements.
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PRODUCTS
2.1PRODUCT SELECTION PROCEDURES
General Product Requirements: Provide products that comply with the Contract Documents,
that are undamaged and, unless otherwise indicated, that are new at time of installation.
Provide products complete with accessories, trim, finish, fasteners, and other items
needed for a complete installation and indicated use and effect.
Standard Products: If available, and unless custom products or nonstandard options
are specified, provide standard products of types that have been produced and used
successfully in similar situations on other projects.
Like items of products furnished and installed shallbe end products of one
manufacturer and of the same series or family of models to achieve standardization
for appearance, operation and maintenance, spare parts and replacement,
manufacturer’s services, and implement same or similar process instrumentation and
control functions.
Provide interchangeable components of the same manufacturer, for similar
components, unless otherwise specified.
OWNER reserves the right to limit selection to products with warranties not in conflict
with requirements of the Contract Documents.
Where products are accompanied by the term "as selected," ENGINEER will make
selection.
Where products are accompanied by the term "match sample," sample to be matched
is ENGINEER’S.
Descriptive, performance, and reference standard requirements in the Specifications
establish "salient characteristics" of products.
Regulatory Requirements: Coating materials shall meet federal, state, and local
requirements limiting the emission of volatile organic compounds and for worker
exposure.
Safety Guards:
Provide for all belt or chain drives, fan blades, couplings, or other moving or
rotary parts. Cover rotating part on all sides. Design foreasy installation and
removal.
Use 16-gauge or heavier; galvanized steel, aluminum, coated steel and ½-inch
mesh expanded steel.
For outdoor installations prevent entrance of rain or dripping water.
Electrical Components: Provide Work in accordance with NFPA 70, National Electrical
code, and be labeled by a nationally recognized testing laboratory or other agency
acceptable to the authority having jurisdiction.
Equipment Finish:
Provide manufacturer’s standard finish and color, except where specific color is
indicted.
If manufacturer does not have a standard color, provide color as approved by
ENGINEER.
Special Tools and Accessories: Provide to OWNER all special tools and accessories
required placing equipment in operation. These include, but not limited to, adequate
oil and grease (as required for first servicing of equipment after field testing), light
bulbs, fuses, hydrant wrenches, valve keys, handwheels, chain operators, special
tools, and other spare parts required for maintenance.
Lubricant: Provide initial lubricant recommended by manufacturer in sufficient
quantity to fill lubricant reservoirs and to replace consumption during testing, start-
up, and operation until final acceptance by OWNER.
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Fabrication and Manufacture:
General Requirements:
Manufacture parts to U.S.A. standard sizes and gauges.
Two or more items of the same type shall be identical, by the same
manufacturer, and interchangeable.
Design structural members for anticipated shock and vibratory loads.
Use 1/4-inch minimum thickness for steel that will be submerged, wholly or
partially, during normal operation.
Modify standard products as necessary to meet performance specifications.
Lubrication System Requirements:
Require no more than weekly attention during continuous operation.
Convenient and accessible. Oil drains, with bronze or stainless steel valves, and
fill-plugs easily accessible from normal operating area or platform. Locate
drains to allow convenient collection of oil during changes without removing
equipment from its installed position.
Provide constant-level oilers or oil level indicators for oil lubrication systems.
For grease type bearings, which are not easily accessible, provide and install
stainless steel tubing; protect and extend tubing to convenient location with
suitable grease fitting.
Product Selection Procedures:
Product: Where Specifications name a single product and manufacturer, provide the
named product that complies with requirements.
Manufacturer/Source: Where Specifications name a single manufacturer or source,
provide a product by the named manufacturer or source that complies with
requirements.
Products: Where Specifications include a list of names of both products and
manufacturers, provide one of the products listed that comply with requirements.
Manufacturers: Where Specifications include a list of manufacturers' names, provide
a product by one of the manufacturers listed that complies with requirements.
Available Products: Where Specifications include a list of names of both products and
manufacturers, provide one of the products listed, or an unnamed product, that
complies with requirements. Comply with provisions in Part2 "Comparable Products"
Article for consideration of an unnamed product.
Available Manufacturers: Where Specifications include a list of manufacturers,
provide a product by one of the manufacturers listed, or an unnamed manufacturer,
that complies with requirements. Comply with provisions in Part2 "Comparable
Products" Article for consideration of an unnamed product.
Product Options: Where Specifications indicate that sizes, profiles, and dimensional
requirements on Drawings are based on a specific product or system, provide the
specified product or system. Comply with provisions in Part2 "Product Substitutions"
Article for consideration of an unnamed product or system.
Basis-of-Design Product: Where Specifications name a product and include a list of
manufacturers, provide the specified product or a comparable product by one of the
other named manufacturers. Drawings and Specifications indicate sizes, profiles,
dimensions, and other characteristics that are based onthe product named. Comply
with provisions in Part2 "Comparable Products" Article for consideration of an
unnamed product by the other named manufacturers.
Visual Matching Specification: Where Specifications require matching an established
Sample, select a product that complies with requirements and matches ENGINEER’S
sample. ENGINEER’S decision will be final on whether a proposed product matches.
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If no product available within specified category matches and complies with
other specified requirements, comply with provisions in Part2 "Product
Substitutions" Article for proposal of product.
Visual Selection Specification: Where Specifications include the phrase "as selected
from manufacturer's colors, patterns, and textures" or a similar phrase, select a
product that complies with other specified requirements.
Standard Range: Where Specifications include the phrase "standard range of
colors, patterns, textures" or similar phrase, ENGINEER will select color,
pattern, density, or texture from manufacturer's product line that does not
include premium items.
Full Range: Where Specifications include the phrase "full range of colors,
patterns, textures" or similar phrase, ENGINER will select color, pattern,
density, or texture from manufacturer's product line that includes both
standard and premium items.
2.2PRODUCT SUBSTITUTIONS
Timing: ENGINEER will consider requests for substitution if received within 30 days after
the Notice to Proceed. Requests received after that time may be considered or rejected at
discretion of ENGINEER.
Conditions: ENGINEER will consider CONTRACTOR’S request for substitution when the
following conditions are satisfied. If the following conditions are not satisfied, ENGINEER
will return requests without action, except to record noncompliance with these
requirements:
Requested substitution offers OWNER a substantial advantage in cost, time, energy
conservation, or other considerations, after deducting additional responsibilities
OWNER must assume. OWNER’S additional responsibilities mayinclude compensation
to ENGINEER for redesign and evaluation services, increased cost of other
construction by OWNER, and similar considerations.
Requested substitution does not require extensive revisions to the Contract
Documents.
Requested substitutionis consistent with the Contract Documents and will produce
indicated results.
Substitution request is fully documented and properly submitted.
Requested substitution will not adversely affect CONTRACTOR’S Construction
Schedule.
Requested substitution has received necessary approvals of authorities having
jurisdiction.
Requested substitution is compatible with other portions of the Work.
Requested substitution has been coordinated with other portions of the Work.
Requested substitution provides specified warranty.
2.3COMPARABLE PRODUCTS
Conditions: ENGINEER will consider CONTRACTOR’S request for comparable product when
the following conditions are satisfied. If the following conditions are not satisfied,
ENGINEER will return requests without action, except torecord noncompliance with these
requirements:
Evidence that the proposed product does not require extensive revisions to the
Contract Documents, which it is consistent with the Contract Documents and will
produce the indicated results, and that it is compatible with other portions of the
Work.
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Detailed comparison of significant qualities of proposed product with those named in
the Specifications. Significant qualities include attributes such as performance,
weight, size, durability, visual effect, and specific features and requirements indicated.
Evidence that proposed product provides specified warranty.
List of similar installations for completed projects with project names and addresses
and names and addresses of architects and owners, if requested.
Samples, if requested.
2.4REUSE OF EXISTING MATERIAL
Except as specifically indicated or specified, materials and equipment removed from existing
facilities shall not be used in the completed Work.
For materials and equipment designated for reuse in the Work:
Use special care in removal, handling, storage, and installation to ensure proper
function in the completed Work.
Arrange for transportation, storage and handling of the products when offsite storage,
restoration, or renovation. All costs associated with this work are the CONTRACTOR’S
responsibility.
2.5TOOLS, SPARE PARTS AND MAINTENANCE MATERIALS
See applicable sections for specific requirements.
Schedule:
Ensure shipment and delivery occurs concurrent with shipment of product.
Transfer to OWNER upon acceptance by CONTRACTOR of shipment.
Packaging and Shipment:
Package and ship items to avoid damage during long term storage in original cartons
or in appropriately sized, hinged-cover, wood, plastic or metal boxes.
Prominently display on each package: Part number, consistent with Operation and
Maintenance Manual identification system; equipment description, quantity of parts;
and equipment manufacturer.
Deliver to designation location as directed by Resident Project Representative.
EXECUTION
3.1WORK IN ACCORDANCE WITH MANUFACTURER’S INSTRUCTIONS
When the specification Section requires the Work to be accomplished in accordance with
“manufacturer’s instructions”, obtain and distribute copies of such instructions to parties
involved in the installation. Provide two copies to the Resident Project Representativeand
maintain one set at the Project site.
Handle, install, connect, clean, condition and adjust products in strict accordance with the
manufacturer’s instructions and in conformity with the Contract Documents. Do not omit any
preparatory step or installation procedures. In case of conflict between job conditions or
Contract Documents with manufacturer’s instructions notify Resident Project Representative.
Upon completion of installation, obtain Certificate of Installation from manufacturer’s
representative.
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3.2INSPECTION
Inspect products for signs of pitting, rust decay, or other deleterious effects of storage. Do
not install products showing such effects. Remove damaged product from Project site and
expedite deliveryof identical new product. Delays to Work resulting from product damage,
which necessitates procurement of new product, will be considered delays within
CONTRACTOR’S control.
3.3INSTALLATION
Drawings show general locations for product installation, unless specially dimensioned.
No shimming between machined surfaces is allowed.
Install Work in accordance with NECA Standard of Installation, unless otherwise specified.
Recoat finish surfaces that are damaged prior to final acceptance of Work.
Do not cut or notch any structural member or building surface without specific approval of
ENGINEER.
Handle, install, connect, clean, condition, and adjust product in accordance with Contract
Documents and manufacturer’s instructions.
Apply field coating in accordance with Contract Documents.
Perform required adjustments, tests, operation checks, and other start-up activities.
Fill lubricant reservoirs and replace consumption during testing, start-up, and operation prior
to final acceptance of Work by OWNER.
3.4SUPPLEMENTS
Sample forms included after “End Of Section” are considered part of this Section:
Substitution Request.
END OF SECTION
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SUBSTITUTION REQUEST
(After the Bidding Phase)
Project: Substitution Request Number:
From:
To: Date:
A/E Project Number:
Re: Contract For:
Specification Title: Description:
Section: Page: Article/Paragraph:
Proposed Substitution:
Manufacturer: Address: Phone:
Trade Name: Model No.:
Installer: Address: Phone:
History: New product 2-5 years old 5-10 yrs old More than 10 years old
Differences between proposed substitution and specified product:
Point-by-point comparative data attached - REQUIRED BY ENGINEER
Reason for not providing specified item:
Similar Installation:
Project: Engineer:
Address: Owner:
Date Installed:
Proposed substitution affects other parts of Work: No Yes; explain
Savings to Owner for accepting substitution: ($ ).
Proposed substitution changes Contract Time: No Yes \[Add\] \[Deduct\] days.
Supporting Data Attached: Drawings Product Data Samples Tests Reports
Copyright 1996, Construction Specification Page of September 1996
Institute CSI Form 13.1A
SUBSTITUTION REQUEST
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0537-038-01 PRODUCT REQUIREMENTS JANUARY 2023
(Continued)
The Undersigned certifies:
Proposed substitution has been fully investigated and determined to be equal or superior in all respects to specified
product.
Same warranty will be furnished for proposed substitution as for specified product.
Same maintenance service and source of replacement parts, as applicable, is available.
Proposed substitution will have no adverse effect on other trades and will not affect or delay progress schedule.
Cost data as stated above is complete. Claims for additional costs related to accepted substitution which may
subsequently become apparent are to be waived.
Proposed substitution does not affect dimensions and functional clearances.
Payment will be made for changes to building design, including A/E design, detailing, and construction costs caused
by the substitution.
Coordination, installation, and changes in the Work as necessary for accepted substitution will be complete in all
respects.
Submitted by:
Signed by:
Firm:
Address:
Telephone:
Attachments:
A/E's REVIEW AND ACTION
Substitution approved - Make submittals in accordance with Specification Section 01 33 00.
Substitution approved as noted - Make submittals in accordance with Specification Section 01 33 00.
Substitution rejected - Use specified materials.
Substitution Request received too late - Use specified materials.
Signed by: Date:
Additional Comments: Contractor Subcontractor Supplier Manufacturer A/E
Page of September 1996
Copyright 1996, Construction Specification
CSI Form 13.1A
Institute,
601 Madison Street, Alexandria, VA 22314-1791
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SECTION 017000
EXECUTION REQUIREMENTS
GENERAL
1.1SUMMARY
This Section includes general procedural requirements governing execution of the Work
including, but not limited to,the following:
Constructionlayout.
Field engineering and surveying.
General installation of products.
Progress cleaning.
Starting and adjusting.
Protection of installed construction.
Correction of the Work.
Basin dewatering and cleaning.
Workmanship.
Firearms.
Handling materials not approved.
Salvaged material.
Archeological discoveries.
Endangered species.
Blasting and burning.
Pipe closure and buoyancy of structures.
OSHA Standards
Related Sections include the following:
Division 1 Section 0143 33“Manufacturers’ Field Services” for information pertaining
to the qualifications and requirements.
1.2RELATEDDOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division1 Specification Sections, apply to this Section.
1.3SUBMITTALS
Certificates: Submit certificate signed by land surveyor certifying that location and elevation
of improvements comply with requirements.
Landfill Receipts: Submit copy of receipts issued by a landfill facility, licensed to accept
hazardous materials, for hazardous wastedisposal.
Certified Surveys: Submit two copies signed by land surveyor.
Final Property Survey: Submit two copies showing the Work performed and record survey
data.
1.4QUALITY ASSURANCE
Land Surveyor Qualifications: A professional land surveyor who is legally qualified to
practice in jurisdiction where Project is located and who is experienced in providing land-
surveying services of the kind indicated.
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PRODUCTS –NOT USED
EXECUTION
3.1EXAMINATION
Existing Conditions and Utilities: When appropriate, the existence and location of site
improvements, underground and other utilities, and other construction indicated as existing
are not guaranteed. Before beginning work, investigate and verify the existence and
location of mechanical and electrical systems and other construction affecting the Work.
Before construction, verify the location and points of connection of utility services.
Before construction, verify the location and invert elevation at points of connection of
sanitary sewer, storm sewer, and water-service piping; and underground electrical
services.
Furnish location data for work related to Project that must be performed by public
utilities serving Project site.
Acceptance of Conditions: Examine substrates, areas, and conditions, with Installer or
Applicator present where indicated, for compliance with requirements for installation
tolerances and other conditions affecting performance. Record observations.
Verify compatibility with and suitability of substrates, including compatibility with
existing finishes or primers.
Examine rough-in for mechanical and electrical systems to verify actual locations of
connections before equipment and fixture installation.
Examine walls, floors, and roofs for suitable conditions where products and systems
are to beinstalled.
Proceed with installation only after unsatisfactory conditions have been corrected.
Proceeding with the Work indicates acceptance of surfaces and conditions.
3.2PREPARATION
Existing Utility Information: Furnish information to local utility that is necessary to adjust,
move, or relocate existing utility structures, utility poles, lines, services, or other utility
appurtenances located in or affected by construction. Coordinate with authorities having
jurisdiction.
Field Measurements: Take field measurements as required to fit the Work properly.
Recheck measurements before installing each product. Where portions of the Work are
indicated to fit to other construction, verify dimensions of other construction by field
measurements before fabrication. Coordinate fabrication schedule with construction
progress to avoid delaying the Work.
Space Requirements: Verify space requirements and dimensions of items shown
diagrammatically on Drawings.
Review of Contract Documents and Field Conditions: Immediately on discovery of the need
for clarification of the Contract Documents, submit a request for information to ENGINEER.
Include a detailed description of problem encountered, together with recommendations for
changing the Contract Documents.
3.3CONSTRUCTION LAYOUT
Verification: Before proceeding to lay out the Work, verify layout information shown on
Drawings, in relation to the property survey and existing benchmarks. If discrepancies are
discovered, notify ENGINEER promptly.
General: Engage a land surveyor to lay out the Work using accepted surveying practices.
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Establish benchmarks and control points to set lines and levels at each story of
construction and elsewhere as needed to locate each element of Project.
Establish dimensions within tolerances indicated. Do not scale Drawings to obtain
required dimensions.
Inform installers of lines and levels to which they must comply.
Check the location, level and plumb, of every major element as the Work progresses.
Notify ENGINEER when deviations from required lines and levels exceed allowable
tolerances.
Close site surveys with an error of closure equal to or less than the standard
established by authorities having jurisdiction.
Site Improvements: Locate and lay out site improvements, including pavements, grading, fill
and topsoil placement, utility slopes, and invert elevations.
Building Lines and Levels: Locate and lay out control lines and levels for structures, building
foundations, column grids, and floor levels, including those required for mechanical and
electrical work. Transfer survey markings and elevations for use with control lines and levels.
Level foundations and piers from two or more locations.
Record Log: Maintain a log of layout control work. Record deviations from required lines
and levels. Include beginning and ending dates and times of surveys, weather conditions,
name and duty of each survey party member, and types of instruments and tapes used.
Make the log available for reference by ENGINEER.
3.4FIELD ENGINEERING
Reference Points: Locate existing permanent benchmarks, control points, and similar
reference points before beginning the Work. Preserve and protect permanent benchmarks
and control points during construction operations.
Benchmarks: Establish and maintain a minimum of two permanent benchmarks on Project
site, referenced to data established by survey control points. Comply with authorities having
jurisdiction for type and size of benchmark.
Record benchmark locations, with horizontal and vertical data, on Project Record
Documents.
Final Property Survey: Prepare a final property survey showing significant features (real
property) for Project. Include on the survey a certification, signed by land surveyor, that
principal metes, bounds, lines, and levels of Project are accurately positioned as shown on
the survey.
3.5INSTALLATION
General: Locate the Work and components of the Work accurately, in correct alignment and
elevation, as indicated.
Make vertical work plumb and make horizontal work level.
Where space is limited, install components to maximize space available for
maintenance and ease of removal for replacement.
Conceal pipes, ducts, and wiring in finished areas, unless otherwise indicated.
Comply with manufacturer's written instructions and recommendations for installing
products in applications indicated.
Install products at the time and under conditions that will ensure the best possible results.
Maintain conditions required for product performance until Substantial Completion.
Conduct construction operations so no part of the Work is subjected to damaging operations
or loading in excess of that expected during normal conditions of occupancy.
Tools and Equipment: Do not use tools or equipment that produces harmful noise levels.
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Templates: Obtain and distribute to the parties involved templates for work specified to be
factory prepared and field installed. Check Shop Drawings of other work to confirm that
adequate provisions are made for locating and installing products to comply with indicated
requirements.
Anchors and Fasteners: Provide anchors and fasteners as required to anchor each
component securely in place, accurately located and aligned with other portions of the
Work.
Mounting Heights: Where mounting heights are not indicated, mount components at
heights directed by ENGINEER.
Allow for building movement, including thermal expansion and contraction.
Coordinate installation of anchorages. Furnish setting drawings, templates, and
directions for installing anchorages, including sleeves, concrete inserts, anchor bolts,
and items with integral anchors, that are to be embedded in concrete or masonry.
Deliver such items to Project site in time for installation.
Joints: Make joints of uniform width. Where joint locations in exposed work are not
indicated, arrange joints for the best visual effect. Fit exposed connections together to form
hairline joints.
Hazardous Materials: Use products, cleaners, and installation materials that are not
considered hazardous.
3.6PROGRESS CLEANING
General: Clean Project site and work areas daily, including common areas. Coordinate
progress cleaning for joint-use areas where more than one installer has worked. Enforce
requirements strictly. Dispose of materials lawfully.
Comply with requirements in NFPA241 for removal of combustible waste materials
and debris.
Do not hold materials more than 7 days during normal weather or 3 days if the
temperature is expected to rise above 80 °F.
Containerize hazardous and unsanitary waste materials separately from other waste.
Mark containers appropriately and dispose of legally, according to regulations.
Site: Maintain Project site free of waste materials and debris.
Work Areas: Clean areas where work is in progress to the level of cleanliness necessary for
proper execution of the Work.
Remove liquid spills promptly.
Where dust would impair proper execution of the Work, broom-clean or vacuum the
entire work area, as appropriate.
Installed Work: Keep installed work clean. Clean installed surfaces according to written
instructions of manufacturer or fabricator of product installed, using only cleaning materials
specifically recommended. If specific cleaning materials are not recommended, use cleaning
materials that are not hazardous to health or property and that will not damage exposed
surfaces.
Concealed Spaces: Remove debris from concealed spaces before enclosing the space.
Exposed Surfaces in Finished Areas: Clean exposed surfaces and protect as necessary to
ensure freedom from damage and deterioration at time of Substantial Completion.
During handling and installation, clean and protect construction in progress and adjoining
materials already in place. Apply protective covering where required to ensure protection
from damage or deterioration at Substantial Completion.
Clean and provide maintenance on completed construction as frequently as necessary
through the remainder of the construction period. Adjust and lubricate operable
components to ensure operability without damaging effects.
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Limiting Exposures: Supervise construction operations to assure that no part of the
construction completed or in progress, is subject to harmful, dangerous, damaging, or
otherwise deleterious exposure during the construction period.
3.7STARTING AND ADJUSTING
Start equipment and operating components to confirmproper operation in accordance with
Section 017525“Equipment Testing and Startup” and the following:
Remove malfunctioning components, replace with new components, and retest.
Adjust operating components for proper operation without binding. Adjust equipment
for proper operation.
Test each piece of equipment to verify proper operation. Test and adjust controls
and safeties. Replace damaged and malfunctioning controls and equipment.
Manufacturer's Services: If a factory-authorized service representative is required to inspect
field-assembled components and equipment installation, comply with qualification
requirements in Section 01 43 33"Manufacturers’ Field Services."
3.8PROTECTION OF INSTALLED CONSTRUCTION
Provide final protection and maintain conditions that ensure installed Work is without
damage or deterioration at time of Substantial Completion.
Comply with manufacturers written instructions for temperature and relative humidity.
3.9CORRECTION OF THE WORK
Repair or remove and replace defective construction. Restore damaged substrates and
finishes.
Repairing includes replacing defective parts, refinishing damaged surfaces, touching
up with matching materials, and properly adjusting operating equipment.
Restore permanent facilities used during construction to their specified condition.
Remove and replace damaged surfaces that are exposed to view if surfaces cannot be
repaired without visible evidence of repair.
Repair components that do not operate properly. Remove and replace operating
components thatcannot be repaired.
Remove and replace chipped, scratched, and broken glass or reflective surfaces.
3.10HAZARDOUS ENVIRONMENT/CONFINED SPACE ENTRY PLANS
CONTRACTOR shall develop and implement Hazardous Environment/Confined Space Entry
Plans for this Project. Plans shall be submitted to the ENGINEER for record purposes prior
to the pre-construction conference. Plans shall include all local, state and federal
requirements for entrance to and working in hazardous environments and confined spaces
and shall include a written safety plan for the Project.
CONTRACTOR shall have a safety officer present at the jobsite whenever the
CONTRACTOR'S activities require entering or working in a hazardous environment or
confined space.
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3.11PLAN OF ACTION
CONTRACTOR shall prepare adetailed, written plan of action covering all shutdowns,
material deliveries, confined space/hazardous environment entries, plant protection system,
construction sequence for major facilities and modifications to existing facilities,
trench/excavation protection, for review and coordination with the OWNER and ENGINEER
at the pre-construction conference. The pre-construction conference will be held prior to
beginning construction activities.
3.12BASIN DEWATERING AND CLEANING
The CONTRACTOR shall clean basins, pipelines and equipment as specified and, when
necessary to complete the work. No additional payment will be made for such work.
Washdown water shall be contained and disposed of properly.
3.13WORKMANSHIP
Specifications contain detailed instructions and descriptions of the major items of
construction and workmanship necessary for building and completing the various elements
of the Project. The Specifications are intended to be written so that only first class
workmanship and finish of the best grade and quality will result. The fact that these
Specifications may fail to be so complete as to cover all details will not relieve the
CONTRACTOR of full responsibility for providing a completed project of high quality, first
class finish and appearance and satisfactory for operation, all within the apparent intent of
the Plans and Specifications.
3.14FIREARMS
Neither the Contractor nor any of his employees shall be allowed to carry firearms on the
Project, either on their persons or within their automobiles. Any violation of this
requirement will result in the permanent removal from the Project of the employee
committing the violation.
3.15HANDLING MATERIALS NOT APPROVED
The CONTRACTOR shall remove from the site any materials found to be damaged, andany
materials not meeting the specifications. These materials shall be removed promptly, unless
the ENGINEER will accept the materials after repairing. Materials found to be damaged, or
not acceptable to the ENGINEER, shall be removed. Examination before installation shall
not relieve the CONTRACTOR from any responsibility to furnish good quality materials.
3.16SURPLUS AND SALVAGED MATERIAL
Surplus equipment or material, which is removed by the CONTRACTOR as specified in the
Drawings and Specifications, shall become the property of the CONTRACTOR. The
CONTRACTOR shall be responsible for the disposal of salvage material offsite.
Equipment and material designated to be salvage shall be transported by the CONTRACTOR
to a location as directed by the Resident Project Representative.
3.17ARCHEOLOGICAL DISCOVERIES
No activity, which may affect a State Archeological Landmark, is authorized until the OWNER
has complied with provisions of the Antiquities Code of Texas. The OWNER has previously
coordinated with the appropriate agencies and impacts to known cultural or archeological
deposits have been avoided or mitigated. However, the CONTRACTOR may encounter
unanticipated cultural or archeological deposits during construction.
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In the event the Contractor discovers any artifacts, cultural materials, or suspected cultural
remains during construction, the Contractor shall contactthe Resident Project
Representativeand American Archaeology Group LLC (512-843-0135) immediately. Any
construction in the immediate vicinity of the suspected cultural deposits shall cease until
they can be examined. Contractor shall in no instance make contact with any parties other
than those referenced above. Contractor shall only restart construction activities in the
vicinity of the suspected cultural deposit upon receipt of written notice from ENGINEERor
OWNER after the issues have been resolved.
3.18ENDANGERED SPECIES
No activity is authorized that is likely to jeopardize the continued existence, or a threatened,
or endangered species as listed, or proposed for listing, under the Federal Endangered
Species Act (ESA), and/or the State of Texas Parks and Wildlife Code on Endangered
Species, or to destroy or adversely modify the habitat of such species.
If a threatened or endangered species is encountered during construction, the
CONTRACTOR shall immediately cease work in the area of the encounter and notify the
Resident Project Representative, who will immediately implement actions in accordance with
the ESA and applicable State statutes. These actions shall include reporting the encounter
to the U.S. Fish and Wildlife Service and the Texas Parks and Wildlife Department, obtaining
any necessary approvals or permits to enable the continuation of work, or implement other
mitigate actions.
TheCONTRACTOR shall not resume construction in the area of the encounter until
authorized to do so by the ResidentProject Representative.
3.19BLASTING AND BURNING
Explosives: Do not use explosives.
BurningandWaste Disposal: Burying or burning waste materials on-site will not be
permitted. Washing waste materials down sewers or into waterways will not be permitted.
Trees and brush removed shall be shredded onsite with disposal off-site.
3.20PIPE CLOSURE AND BUOYANCY OF STRUCTURES
At the end of each working day, the CONTRACTOR shall plug the ends of all exposed
pipeline to prevent any material or objects from entering the pipeline.
The CONTRACTOR shall anchor all pipelines and structures to prevent their flotation should
rain occur prior to the completion of backfilling to proposed final grade.
3.21OSHA STANDARDS
All work performed under this Contract shall meet the applicable requirements of the
Occupational Safety and Health Administration (OSHA). It is the responsibility of the
CONTRACTOR to become familiar with the provisions of regulations published by OSHA in
the Federal Register and to perform all of the responsibilities thereunder. It is the
CONTRACTOR’s responsibility to see that the Project is constructed in accordance with OSHA
regulations and to indemnify and save harmless the OWNER from any penalties resulting
from the CONTRACTOR’s failure to so perform.
END OF SECTION
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0537-038-01 EXECUTION REQUIREMENTS JANUARY 2023
SECTION 01 71 23
FIELD ENGINEERING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Requirements for Contractor’s onsite recordkeeping.
2. Contractor’s field engineering.
3. Contractor’s surveying and layouts, and associated requirements.
4. This section supplements the General Conditions’ provisions on reference points and
other matters.
B. Scope:
1. Contractor shall provide onsite recordkeeping, field engineering (not related to design
of the completed Work), surveying and layout services, and professional services of
the types indicated for the Project, including:
a. Furnishing civil, structural, geotechnical, electrical, and other professional
engineering and geology services, whether required by the Contract Documents
or necessary in Contractor’s judgment, to perform Contractor’s means,
methods, techniques, sequences, and procedures of construction. Such
services do not include professional services associated with delegation of
professional design responsibility, which (when required as part of the Work) is
addressed elsewhere in the Contract Documents.
b. Developing and making all detail surveys and measurements required for
construction; including slope stakes, batter boards, and all other working lines,
elevations, and cut sheets.
c. Providing materials required for Contractor’s benchmarks, control points, batter
boards, grade stakes, structure and pipeline elevation stakes, and other items.
d. Keeping a transit, theodolite, or total station (i.e., theodolite with electronic
distance measurement device); leveling instrument; and related implements
such as survey rods and other measurement devices, at the Site at all times,
and having a skilled instrument person available when necessary for laying out
the Work and verifying lines, grades, and elevations.
e. Being solely responsible for all locations, dimensions, and levels of the Work.
No data other than Change Order, Work Change Directive, or Field Order shall
justify departure from dimensions and levels required by the Contract
Documents.
f. Rectifying all Work improperly installed because of not maintaining, not
protecting, or removing without authorization established reference points,
stakes, marks, and monuments.
g. Providing such facilities and assistance necessary for Engineer and Resident
Project Representative (if any) or Owner’s Site Representative (if any) to check
lines and grade points placed by Contractor.
1.2 PRICE AND PAYMENT PROCEDURES
A. Unit Price Work:
1. Do not perform excavation or embankment work until all cross-sectioning necessary
for determining payment quantities for Unit Price Work have been completed and
accepted by Engineer.
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1.3 ADMINISTRATIVE REQUIREMENTS
A. Coordination:
1. Review requirements of this and other Specifications sections and coordinate other
elements of the Work with field engineering, surveying, and layout Work and
recordkeeping obligations set forth in this Specifications section.
1.4 SUBMITTALS
A. Informational Submittals: Submit the following:
1. Certificates:
a. When requested by Engineer following completion of the Work or a part
thereof, submit certificate signed by professional engineer or professional
surveyor, as applicable, indicating that elevations and locations of the Work
comply with the Contract Documents. Explain each discrepancy, if any, from
the requirements of the Contract Documents.
2. Contractor’s Daily Reports and Field Engineering Records:
a. Submit daily reports as indicated in this Specification Section.
b. When requested by Engineer, submit documentation verifying accuracy of field
engineering.
3. Contractor’s Surveying Plan and Records:
a. Complete plan for performing surveying Work, submitted not less than 10 days
prior to beginning surveying Work.
b. Example of proposed surveying field books to be maintained by Contractor’s
surveyor. Example surveying field book shall have sufficient information and
detail, including example calculations and notes, to demonstrate that surveying
field books will be organized and maintained in a professional manner in
accordance with the Contract Documents.
c. Submit original surveying field books within two days after completing
surveying Work.
d. Submit certified survey in accordance with this Specifications’ section.
4. Qualifications Statements:
a. Field Engineer: Name, employer, and professional address. When requested
by Engineer, submit qualifications, including detailed resume’.
b. Surveyor: Name, employer, professional address of firm, and detailed resumes
of each professional land surveyor and crew chief that will be engaged in
surveying Work. Submit not less than 10 days prior to beginning surveying
Work. During the Project, submit detailed resume’ for each new registered,
licensed land surveyor and crew chief employed by or retained by Contractor
not less than 10 days prior to starting on the surveying Work.
1.5 CONTRACTOR’S ENGINEERS
A. Qualifications of Contractor’s Field Engineer:
1. Employ and retain at the Site a field engineer with experience and capability of
performing all field engineering tasks required of Contractor, as indicated in this
Article and elsewhere in the Contract Documents.
2. Contractor’s field engineer shall possess not less than five years of experience
performing duties similar in scope and complexity to those required of Contractor’s
field engineer on this Project.
3. Contractor’s field engineer may serve as Contractor’s Site superintendent, or as the
recorder of as-constructed conditions in accordance with Section 01 78 39 - Project
Record Documents, or as any combination of these roles as deemed appropriate by
Contractor.
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4. Maintain at the Site full-time superintendent or field engineer fluent in written and
spoken English language.
B. Responsibilities of Contractor’s Field Engineer:
1. Daily Reports:
a. Prepare and maintain daily reports of activity on the Contract. Submit reports
to Engineer. Contractor’s daily reports shall indicate the following information:
1) Contractor’s Employees: Number of Contractor’s employees at the Site,
apportioned by trade(s).
2) Subcontractors: Separately indicate and identify each Subcontractor and
the number of workers onsite for each. Apportion number of workers by
trade(s).
3) Equipment and materials installed as part of the Work.
4) Equipment and materials, to be installed in the Work, delivered to the
Site or offsite storage location that day. When delivered to offsite
storage, indicate the storage location.
5) Major construction equipment utilized by major activity. Indicate for
each manufacturer, model number, and year of manufacture.
6) Location of areas in which construction was performed.
7) Work performed, including field quality control activities such as
inspections and testing. Indicate field quality control activities witnessed
by Engineer, Resident Project Representative (if any), or Owner’s Site
Representative (if any).
8) Weather conditions, including minimum and maximum ambient air
temperatures, relative humidity, conditions of high winds or other
extreme weather, and precipitation.
9) Safety concerns, events, and precautions taken.
10) Defective Work observed or believed to exist.
11) Delays encountered, extent of delay incurred, reasons for the delay, and
measures that will be taken to rectify delays encountered.
12) Acknowledgement of specific instructions received from Engineer,
Resident Project Representative (if any), Owner, or Owner’s Site
Representative (if any).
13) Visitors to the Site.
14) Other notable events occurring on the Project.
b. Daily reports shall be signed and dated by responsible member of Contractor’s
staff, such as Contractor's field engineer, superintendent, project manager, or
foreman designated by Contractor as having authority to sign daily reports.
c. Submit Contractor’s daily reports by 9:00 a.m. (local time at the Site) the next
working day after the day covered in the associated report.
2. Check all formwork, reinforcing materials, inserts, structural steel, masonry,
insulation, waterproofing and element protection, doors and windows, finishes, bolts,
sleeves, piping, other materials and equipment for compliance with the Contract
Documents.
3. Continually inspect the Work to ensure that the quality and quantities required by the
Contract Documents are provided.
4. Promptly report defective Work to Contractor, Engineer, Resident Project
Representative (if any), and Owner’s Site Representative (if any).
5. Cooperate as required with Engineer, Resident Project Representative (if any), and
Owner’s Site Representative (if any) in observing the Work and performing field
inspections and other field quality control activities.
6. Check and coordinate the Work for conflicts and interferences, and immediately
advise Engineer and Resident Project Representative (if any) of all discrepancies of
which Contractor is aware.
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7. Maintain field office files and drawings, record documents, and coordinate field
engineering services with Subcontractors and Suppliers as appropriate, and other
prime contractors (if any).
8. Supervise or personally prepare and maintain Project record documents in accordance
with Section 01 78 39 - Project Record Documents.
9. Prepare layout and coordination drawings for construction operations.
10. Review and coordinate the Work with Shop Drawings approved by Engineer, other
Submittals accepted by Engineer, and Contractor's means, methods, techniques,
sequences, and procedures of construction and safety programs incident thereto.
11. Coordinate onsite work of Subcontractors and Suppliers, or assist Contractor’s Site
superintendent in doing so.
C. Design Professionals Services Retained by Contractor (whether or not stationed at the Site):
12. Delegated Professional Design Services:
a. Where the Contract Documents require Contractor to furnish professional
engineering, geology, or architecture services as delegated professional design,
the provisions of the General Conditions, Specifications, and other Contract
Documents regarding delegated design responsibility apply.
13. Design Professional Services that are Not Delegated Professional Design of the
Completed Work:
a. Where the Contract Documents require that Contractor retain a design
professional such as a professional engineer, geologist, or architect, or when in
Contractor’s judgment retaining such entity is necessary for implementing
Contractor’s means, methods, techniques, sequences, or procedures of
construction or safety and protection programs incident thereto, retain a design
professional with necessary skills, experience, and qualifications to perform the
required services. Where required by the Contract Documents or by Laws or
Regulations, such entity shall be duly licensed and registered to perform the
associated design professional services in the same jurisdiction as the Site,
unless otherwise allowed by Laws or Regulations or by the Contract
Documents.
b. Owner and Engineer shall be entitled to rely upon the adequacy, accuracy, and
completeness of the services, certifications, and approvals performed by such
design professional(s).
1.6 CONTRACTOR’S SURVEYOR
A. Qualifications:
1. Employ or retain the services, as needed, at the Site a surveyor with experience and
capability of performing surveying and layout tasks required in the Contract
Documents and as required for the Work. Comply with Laws and Regulations
governing land surveying.
2. Contractor’s surveyor shall possess not less than five years of experience performing
duties similar in scope and complexity to those required of Contractor’s surveyor on
this Project.
B. Responsibilities of Contractor’s Surveyor:
1. Providing required surveying equipment, including transit, theodolite, or total station;
level; stakes; and surveying accessories.
2. Establishing required lines and grades for constructing all facilities, structures,
pipelines, and site improvements, including outdoor electrical equipment and feeders.
3. Preparing and maintaining professional-quality, accurate, well-organized, legible notes
of all measurements and calculations made while surveying and laying out the Work.
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4. Prior to backfilling operations, survey, locate, and record on a copy of the Drawings
accurate representation of buried Work and Underground Facilities provided and
encountered.
5. Locating on a site plan of the Site the actual location of above-groundwork to be
indicated on record documents.
6. Complying with requirements of the Contract Documents relative to surveying and
related Work, including requirements of this Specification section’s Articles 1.6 and
3.1.
1.7 RECORDS
A. Records – General:
1. Maintain at the Site:
a. Contractor’s field engineer’s daily reports, with information and submitted in
accordance with Article 1.5 of this Specification Section.
b. Information and documents required by Section 01 78 39 - Project Record
Documents.
c. Complete and accurate log of control and survey Work as such Work
progresses.
d. Other records deemed by Contractor to be necessary or appropriate.
B. Field Books and Records:
1. Survey data and records shall be in accordance with recognized professional
surveying standards, Laws and Regulations, and prevailing standard of care in the
locality where the Site is located.
2. Original field notes, calculations, and other surveying data shall be recorded by
Contractor’s surveyor in Contractor-furnished hard-bound field books, and shall be
signed by Contractor’s surveyor.
3. Completeness and accuracy of surveying Work, and completeness and accuracy of
surveying records, including field books, shall be responsibility of Contractor.
4. Unacceptable Records of Contractor’s Surveyor:
a. Failure to organize and maintain survey records in an appropriate manner that
allows reasonable and independent verification of calculations, and to allow
identification of elevations, lines, locations, dimensions, and grades of the
Work, shall be cause for rejecting the surveying records, including field books.
b. Illegible notes or data, and erasures on any page of field books, are
unacceptable. Do not submit copied notes or data. Corrections by ruling or
lining out errors will be unacceptable unless initialed by the surveyor. Violation
of these requirements may require re-surveying the data questioned by
Engineer.
c. Other provisions of the Contract notwithstanding, Contractor shall have sole
responsibility for uncovering, re-surveying, and restoring uncovered Work
should survey data be unacceptable to Engineer.
C. Survey of Surface Structures:
1. Upon completion of foundations and major site improvements, prepare a survey,
showing or indicating dimensions, locations, angles and elevations of construction and
locations and elevations of Underground Facilities installed and encountered during
the Work.
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PART 2 - PRODUCTS - (NOT USED)
PART 3 - EXECUTION
3.1 SURVEYING
A. Reference Points:
1. Refer to the General Conditions, as may be modified by the Supplementary
Conditions, for requirements regarding reference points.
2. Owner’s established reference points that are damaged or destroyed by Contractor
will be re-established by Owner at Contractor’s expense. Owner may deduct from
payments due Contractor such amounts as set-offs in accordance with the Contract
Documents.
3. From Owner-established reference points, establish lines, grades, and elevations
necessary to control the Work. Obtain measurements required for performing the
Work to tolerances indicated in the Contract Documents.
4. Establish, place, and replace as required, such additional stakes, markers, and other
reference points necessary for controlling the Work and verifying accuracy and
compliance with the Contract Documents.
B. Surveys to Determine Quantities for Payment:
1. For each application for progress payment, perform such surveying and calculations
necessary to determine quantities of Work performed or placed, including Unit Price
Work. Perform surveying necessary for Engineer to determine final quantities of
Work in place.
2. Advise Engineer, Resident Project Representative (if any), and Owner’s Site
Representative (if any) not less than 24 hours before performing surveying services
for determining quantities to be included in Application for Payment. Unless waived in
writing by Engineer, perform quantity surveys in presence of Engineer or Resident
Project Representative (if any).
C. Construction Surveying: Comply with the following:
1. Alignment Staking: Provide alignment stakes at 50 FT intervals on tangent, and at 25
FT intervals on curves.
2. Slope Staking: Provide slope staking at 50 FT intervals on tangent, and at 25 FT
intervals on curves. Re-stake at every ten-foot difference in elevation.
3. Structure: Stake-out structures, including elevations, and check prior to and during
construction.
4. Pipelines: Stake-out pipelines including elevations, and check prior to and during
construction.
5. Roads, Drives, and Paved Areas: Stake-out roadway, driveway, and paved area
elevations at 50-foot intervals on tangent, and at 25 FT intervals on curves.
6. Cross-Sections: Provide original, intermediate, and final staking as required, for site
work and other locations as necessary for quantity surveying.
7. Easement Staking: Provide easement staking at 50 FT intervals on tangent, and at 25
FT intervals on curves. Also provide wooden laths with flagging at maximum intervals
of 100 FT.
8. Record Staking: Provide permanent stake at each blind flange and each utility cap
provided for future connections. Stakes for record staking shall be material
acceptable to Engineer, durably installed for long-term reference by Owner, utility
owners, and others as necessary.
D. Accuracy:
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1. Establish Contractor's temporary survey references points for Contractor’s use to not
greater than second-order accuracy (i.e., 1:10000). Construction staking used as a
guide for the Work shall be set at not greater than third-order accuracy (i.e., 1:5000).
Basis on which such orders are established shall provide the absolute margin for error
specified below.
2. Horizontal accuracy of easement staking shall be plus or minus 0.1 FT. Accuracy of
other staking shall be plus or minus 0.04 FT horizontally and plus or minus 0.02 FT
vertically.
3. Survey calculations shall include an error analysis sufficient to demonstrate required
accuracy.
END OF SECTION
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SECTION 01 73 29
CUTTING AND PATCHING
GENERAL
1.1SUMMARY
This Section includes procedural requirements for cutting and patching.
1.2RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division1 Specification Sections, apply to this Section.
Related Sections include the following:
Section 02 41 19"Selective Demolition" for demolition of selected portions of the
facilities.
Divisions2 through 19Sections for specific requirements and limitations applicable to
cutting and patching individual parts of the Work.
1.3SUBMITTALS
Cutting and Patching Proposal: Submit a proposal describing procedures at least 10 days
before the time cutting and patching will beperformed, requesting approval to proceed.
Include the following information:
Extent: Describe cutting and patching, show how they will be performed, and
indicate why they cannot be avoided.
Changes to In-Place Construction: Describe anticipated results. Include changes to
structural elements and operating components as well as changes in building's
appearance and other significant visual elements.
Products: List products to be used and firms or entities that will perform the Work.
Dates: Indicate when cutting and patching will be performed.
Utility Services and Mechanical/Electrical Systems: As applicable, list services/systems
that cutting and patching procedures will disturb or affect. List services/systems that
will be relocated and those that will be temporarily out of service. Indicate how long
services/systems will be disrupted.
Structural Elements: Where cutting and patching involve adding reinforcement to
structural elements, submit details and engineering calculations showing integration
of reinforcement with original structure.
ENGINEER’S Approval: Obtain approval of cutting and patching proposal before
cutting and patching. Approval does not waive right to later require removal and
replacement of unsatisfactory work.
1.4QUALITY ASSURANCE
Structural Elements: Do not cut and patch structural elements in a manner that could
change their load-carrying capacity or load-deflection ratio.
Operational Elements: Do not cut and patch operating elements and related components in
amanner that results in reducing their capacity to perform as intended or that result in
increased maintenance or decreased operational life or safety.
Miscellaneous Elements: Do not cut and patch miscellaneous elements or related
components in a manner that could change their load-carrying capacity, which results in
reducing their capacity to perform as intended, or that result in increased maintenance or
decreased operational life or safety.
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Visual Requirements: Do not cut and patch construction in a manner that results in visual
evidence of cutting and patching. Do not cut and patch construction exposed on the
exterior or in occupied spaces in a manner that would, in Architect's opinion, reduce the
building's aesthetic qualities. Remove and replace construction that has been cut and
patched in a visually unsatisfactory manner.
PRODUCTS
2.1MATERIALS
General: Comply with requirements specified in other Sections.
In-Place Materials: Use materials identical to in-place materials. For exposed surfaces, use
materials that visually match in-place adjacent surfaces to the fullest extent possible.
If identical materials are unavailable or cannot be used, use materials that, when
installed, will match the visual and functional performance of in-place materials. The
material selected must be approved by the ENGINEERbefore it can be used.
EXECUTION
3.1EXAMINATION
The CONTRACTOR shall make his own investigations and determine the nature of work
involved in making the connections and modifications to existing facilities in the manner
intended by the Plans.
Sequencing and coordination requirements are described elsewhere.
Examine surfaces to be cut and patched and conditions under which cutting and patching
are to be performed.
Compatibility: Before patching, verifycompatibility with and suitability of substrates,
including compatibility with in-place finishes or primers.
Proceed with installation only after unsafe or unsatisfactory conditions have been
corrected.
3.2PREPARATION
Temporary Support: Provide temporary support of Work to be cut.
Protection: Protect in-place construction during cutting and patching to prevent damage.
Provide protection from adverse weather conditions for portions of Project that might be
exposed during cutting and patching operations.
Adjoining Areas: Avoid interference with use of adjoining areas or interruption of free
passage to adjoining areas.
Existing Utility Services and Mechanical/Electrical Systems: Where existing services/systems
are required to be removed, relocated, or abandoned, bypass such services/systems before
cutting to prevent interruption to occupied areas, if applicable.
3.3PERFORMANCE
General: Employ skilled workers to perform cutting and patching. Proceed with cutting and
patching at the earliest feasible time,and complete without delay.
Cut in-place construction to provide for installation of other components or
performance of other construction, and subsequently patch as required to restore
surfaces to their original condition.
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Cutting: Cut in-place construction by sawing, drilling, breaking, chipping, grinding, and
similar operations, including excavation, using methods least likely to damage elements
retained or adjoining construction. If possible, review proposed procedures with original
Installer; complywith original Installer's written recommendations.
In general, use hand or small power tools designed for sawing and grinding, not
hammering and chopping. Cut holes and slots as small as possible, neatly to size
required, and with minimum disturbance of adjacent surfaces. Temporarily cover
openings when not in use.
Finished Surfaces: Cut or drill from the exposed or finished side into concealed
surfaces.
Concrete and Masonry: Cut using a cutting machine, such as an abrasive saw or a
diamond-core drill.
Excavating and Backfilling: Comply with requirements in applicable Division31
Sections where required by cutting and patching operations.
Mechanical and Electrical Services: Cut off pipe or conduit in walls or partitions to be
removed. Cap, valve, or plug and seal remaining portion of pipe or conduit to prevent
entrance of moisture or other foreign matter after cutting.
Proceed with patching after construction operations requiring cutting are complete.
Patching: Patch construction by filling, repairing, refinishing, closing up, and similar
operations following performance of other Work. Patch with durable seams that are as
invisible as possible. Provide materials and comply with installation requirements specified
in other Sections.
Inspection: Where feasible, test and inspect patched areas after completion to
demonstrate integrity of installation.
Exposed Finishes: Restore exposed finishes of patched areas and extend finish
restoration into retained adjoining construction in a manner that will eliminate
evidence of patching and refinishing.
Floors and Walls: Where walls or partitions that are removed extend one finished
area into another, patch and repair floor and wall surfaces in the new space. Provide
an even surface of uniform finish, color, texture, and appearance. Remove in-place
floor and wall coverings and replace with new materials, if necessary, to achieve
uniform color and appearance.
Ceilings: Patch, repair, or rehang in-place ceilings as necessary to provide an even-
plane surface of uniform appearance.
Exterior Building Enclosure: Patch components in a manner that restores enclosure to
a weathertight condition.
The CONTRACTOR shall dewater and clean existing basins, pipelines and equipment as
specified and, when necessary to completethe work, shall be the responsibility of the
CONTRACTOR. No additional payment will be made for such work.
Cleaning: Clean areas and spaces where cutting and patching are performed. Completely
remove paint, mortar, oils, putty, and similar materials.
END OF SECTION
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SECTION 01 75 25
EQUIPMENT TESTING AND STARTUP
GENERAL
1.1SUMMARY
SUPPLIER’s scope of work to be performed under this specification shall be to support
installation, testing and startup of all supplied equipment systems.
1.2REFERENCES –NOT USED
1.3ADMINISTRATIVE REQUIREMENTS
Service of SUPPLIER’s/MANUFACTURER’s Representative
SUPPLIER’s/MANUFACTURER’s contracted cost for the equipment shall include the
cost of furnishing competent and experienced personnel who shall represent the
manufacturers and shall assist the CONTRACTOR, when required, to renovate or
install, adjust, andtest the equipment in conformity with the Contract Documents.
After the equipment is placed in permanent operation by the CONTRACTOR,
SUPPLIER’s/MANUFACTURER’spersonnel shall make all adjustments and tests
required to prove that such equipment is in proper and satisfactory operating
condition and shall instruct the OWNER's representatives in the proper operation and
maintenance of such equipment or system. Training must be adequate and
acceptable to OWNER’s representative. The preliminaryEquipment O&M must be
approved prior to start of training.
1.4SUBMITTALS
Submit to ENGINEER, for review, start-up and test schedule a minimum of 60 days prior to
commencing Work specified in this section.
Submit to ENGINEER an electronic copy and aminimum of two(2) hard copies of field test
data and test records for all equipment and systems.
PRODUCTS
2.1FURNISH INITIAL LUBRICANTS AND OTHER CONSUMABLES
CONTRACTOR shall furnish and install initial supply of oil, grease or other consumable
required per SUPPLIER’s/MANUFACTURER’s instructions to startup, test and place into
service the supplied equipment.
EXECUTION
3.1TESTING AND STARTUP PLAN
Submit a plan thatincludes a schedule for testing and startup of all equipment and systems
provided as part of the Work. Specific Tests for each piece of equipment are detailed in the
Equipment Specification Section.
Include in the startup plan:
Sequences.
Lock-out procedures and safety precautions.
Utility requirements.
Related items and piping which must be complete and the schedule for completion.
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Instrumentation settings.
Operation Support
SUPPLIER/MANUFACTURERshall provide a schedule and outline for training of OWNER's
personnel. Equipment shall not be turned over to OWNERprior to training of OWNER's
personnel. Specifically identify adjustment and maintenance items that must be done in
initial 30-day period.
3.2PREPARATION
SUPPLIER/MANUFACTURERshall verify that the CONTRACTOR has performed the following
work prior to testing and startup:
Complete equipment installation with controls, safety devices and auxiliary support
systems necessary to start the equipment and verify that the equipment functions
correctly under no load conditions.
Remove temporary bracing supports and other construction debris that may damage
equipment.
Remove protective coatings and oils from new equipment used for protection during
shipment and installation.
Flush and fill lubricated systems in equipment in accordance with Manufacturer's
instructions.
On new equipment, install temporary connections and devices required to fill,
operate, checkout and drain the system.
Check equipment for correct direction of rotation and freedom of moving parts.
Align equipment to Manufacturer's tolerances.
Check installation prior to start-up for conformance to Manufacturer's instructions.
Adjust or modify equipment to make equipment properly operational.
Correct any deficiencies or problems noted in Manufacturer's representative's
installation reports.
Complete testing of related piping systems and furnish test reports to ENGINEER.
3.3TESTING AND STARTUP
SUPPLIER shall perform the following:
SUPPLIER/MANUFACTURERwith CONTRACTOR assistance as required shall begin
checkout, testing, and startup procedures after training of OWNER's personnel and
approval by ENGINEER of testing and startup plan. SUPPLIER/MANUFACTURER's
installation report shall be submitted within 48hours of startup.
Make final connections to equipment and complete the system installation necessary
to apply the system loads to the equipment and verify the equipment functions
correctly.
Perform all tests as required by the specifications prior to startup.
Start equipment according to manufacturer's instructions.
Place each piece of equipment in the system in operation until the entire system is
functioning.
Operate the system through the design performance range consistent with available
flows. Adjust, balance, and calibrate and, in general, check out the equipment, safety
devices, controls, and process system to operate within the design conditions.
END OF SECTION
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SECTION 017700
CLOSEOUT PROCEDURES
GENERAL
1.1SUMMARY
This Section includes administrative and procedural requirements for contract closeout,
including, but not limited to, the following:
Inspection procedures.
Final cleaning.
1.2RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division1 Specification Sections, apply to this Section.
Related Sections include the following:
Section 017000 "Execution Requirements" for progress cleaning of Project site.
Section 017839"Project Record Documents" for submitting Record Drawings,
Record Specifications, and Record Product Data.
Section 017823"Operation and Maintenance Data" for operation and maintenance
manual requirements.
Section 0179 00"Demonstration and Training" for requirements for instructing
Owner's personnel.
All other Contract Document sectionsfor specific closeout and special cleaning
requirements for the Work in those Sections.
1.3SUBSTANTIAL COMPLETION
Preliminary Procedures: Before requesting inspection for determining date of Substantial
Completion, complete the following. List items below that are incomplete in request.
Prepare a list of items to be completed and corrected (punch list), the value of items
on the list, and reasons why the Work is not complete.
Advise OWNER of pending insurance changeover requirements.
Submit specific warranties, workmanship bonds, maintenance service agreements,
final certifications, and similar documents.
Obtain and submit releases permitting Owner unrestricted use of the Work and access
to services and utilities. Include occupancy permits, operating certificates, and similar
releases.
Prepare and submit Project Record Documents, operation and maintenance manuals,
Final Completion construction photographs, damage or settlement surveys, property
surveys, and similar final record information.
Deliver tools, spare parts, extra materials, and similar items to location designated by
OWNER. Label with manufacturer's name and model number where applicable.
Make final changeover of permanent locks and deliver keys to OWNER. Advise
OWNER’S personnel of changeover insecurity provisions.
Complete startup testing of systems.
Submit test/adjust/balance records.
Terminate and remove temporary facilities from Project site, along with mockups,
construction tools, and similar elements.
Advise OWNER of changeover in heat andother utilities.
Submit changeover information related to OWNER’S occupancy, use, operation, and
maintenance.
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Complete final cleaning requirements, including touchup painting.
Touch up and otherwise repair and restore marred exposed finishes to eliminate
visual defects.
Inspection: Submit a written request for inspection for Substantial Completion. On receipt
of request, ENGINEER will either proceed with inspection or notify CONTRACTOR of
unfulfilled requirements. ENGINEER will prepare the Certificate of Substantial Completion
after inspection or will notify CONTRACTOR of items, either on CONTRACTOR’S list or
additional items identified by ENGINEER, which must be completed or corrected before
certificate will be issued.
Reinspection: Request reinspection when the Work identified in previous inspections
as incomplete is completed or corrected.
Results of completed inspection will form the basis of requirements for Final
Completion.
1.4FINAL COMPLETION
Preliminary Procedures: Before requesting final inspection for determining date of Final
Completion, complete the following:
Submit a final Application for Payment according tothe provisions in the Agreement
Form.
Submit certified copy of ENGINEER’S Substantial Completion inspection list of items to
be completed or corrected (punch list), endorsed and dated by ENGINEER. The
certified copy of the list shall state that each item has been completed or otherwise
resolved for acceptance.
Submit evidence of final, continuing insurance coverage complying with insurance
requirements.
Submit pest-control final inspection report and warranty, as applicable.
Instruct Owner's personnel in operation, adjustment, and maintenance of products,
equipment, and systems. Submit demonstration and training videotapes.
Inspection: Submit a written request for final inspection for acceptance. On receipt of
request, ENGINEER will either proceed with inspection or notify CONTRACTOR of unfulfilled
requirements. ENGINEER will prepare a final Certificate for Payment after inspection or will
notify Contractor of construction that must be completed or corrected before certificate will
be issued.
Reinspection: Request reinspection when the Work identified in previous inspections
as incomplete is completed or corrected.
The retainage and its interest earnings, if any, shall not be paid to the Contractor until the
OWNER, and/or TWDB or other funding agency, has authorized a reduction in, or release of,
retainage on the contract work.
1.5LIST OF INCOMPLETE ITEMS (PUNCH LIST)
Preparation: Submit three(3)copies of list. Include name and identification of each space
and area affected by construction operations for incomplete items and items needing
correction including, if necessary, areas disturbed by Contractor that are outside the limits of
construction.
Organize list in sequential order.
Organize items applying to each space by major element.
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PRODUCTS
2.1MATERIALS
Cleaning Agents: Use cleaning materials and agents recommended by manufacturer or
fabricator of the surface to be cleaned. Do not use cleaning agents that are potentially
hazardous to health or property or that might damage finished surfaces.
EXECUTION
3.1FINAL CLEANING
General: Provide final cleaning. Conduct cleaning and waste-removal operations to comply
with local laws and ordinances and Federal and local environmental and antipollution
regulations.
Cleaning: Employ experienced workers or professional cleaners for final cleaning. Clean
each Project site, equipment, structures, buildings and related facilities. Comply with
manufacturer's written instructions.
Complete the following cleaning operations before requesting inspection for
certification of Substantial Completion for entire Project or for a portion of Project:
Clean Project site, yard, and grounds, in areas disturbed by construction
activities, including landscape development areas, of rubbish, waste material,
litter, and other foreign substances.
Sweep paved areas broom clean. Remove petrochemical spills, stains, and
other foreign deposits.
Rake grounds that are neither planted nor paved to a smooth, even-textured
surface.
Remove tools, construction equipment, machinery, and surplus material from
Project site.
Clean exposed exterior and interior hard-surfaced finishes to a dirt-free
condition, free of stains, films, and similar foreign substances. Avoid disturbing
natural weathering of exterior surfaces. Restore reflective surfaces to their
original condition.
Remove debris and surface dust from limited access spaces, including roofs,
plenums, shafts, trenches, equipment vaults, manholes, attics, and similar
spaces.
Sweep concrete floors broom clean in unoccupied spaces.
Vacuum carpet and similar soft surfaces, removing debris and excess nap;
shampoo if visible soil or stains remain.
Clean transparent materials, including mirrors and glass in doors and windows.
Remove glazing compounds and other noticeable, vision-obscuring materials.
Replace chipped or broken glass and other damaged transparent materials.
Polish mirrors and glass, taking care not to scratch surfaces.
Remove labels that are not permanent.
Touch up and otherwise repair and restore marred, exposed finishes and
surfaces. Replace finishes and surfaces that cannot be satisfactorily repaired or
restored or that already show evidence of repair orrestoration.
Do not paint over "UL" and similar labels, including mechanical and
electrical nameplates.
Wipe surfaces of mechanical and electrical equipment and similar equipment.
Remove excess lubrication, paint and mortar droppings, and other foreign
substances.
Replace parts subject to unusual operating conditions.
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Clean plumbing fixtures to a sanitary condition, free of stains, including stains
resulting from water exposure.
Replace disposable air filters and clean permanent air filters. Clean exposed
surfaces of diffusers, registers, and grills.
Clean light fixtures, lamps, globes, and reflectors to function with full efficiency.
Replace burned-out bulbs, and those noticeably dimmed by hours of use, and
defective and noisy starters in fluorescent and mercury vapor fixtures to
comply with requirements for new fixtures.
Leave Project clean and ready for occupancy.
Pest Control: Engage an experienced, licensed exterminator to make a final inspection and
rid Project of rodents, insects, and other pests. Prepare a report.
Comply with safety standards for cleaning. Do not burn waste materials. Do not bury
debris or excess materials on Owner's property. Do not discharge volatile, harmful, or
dangerous materials into drainage systems. Remove waste materials from Project site and
dispose of lawfully.
END OF SECTION
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SECTION 01 78 23
OPERATION AND MAINTENANCE DATA
GENERAL
1.1SUMMARY
This Section includes administrative and procedural requirements for preparing operation
and maintenance manuals, including the following:
Operationand maintenance documentation directory.
Emergency manuals.
Operation manuals for systems, subsystems, and equipment.
Maintenance manuals for the care and maintenance of systems and equipment.
Related Sections include the following:
Section 01 33 00“SubmittalProcedures"for submitting copies of submittals for
operation and maintenance manuals.
Section 01 70 00“Execution Requirements”for submitting operation and maintenance
manuals.
Section 017839"Project Record Documents" for preparing Record Drawings for
operation and maintenance manuals.
All other Contract Documentsfor specific operation and maintenance manual
requirements for the Work in those Sections.
1.2REFERENCES
Preselection Drawings and general provisions of the Contract, including Preselection Special
Conditions and Division 01 Specification Sections, apply to this Section.
Definitions
Preliminary Data: Initial and subsequent submissions for ENGINEER’S review.
Final Data: ENGINEER accepted data, submitted as specified herein.
Maintenance Operation: As used on Maintenance Summary Form is defined to mean
any routine operation required to ensure satisfactory performance and longevity of
equipment. Examples of typical maintenance operations are lubrication, belt
tensioning, adjustment ofpump packing glands, and routine adjustments.
System: An organized collection of parts, equipment, or subsystems united by regular
interaction.
Subsystem: A portion of a system with characteristics similar to a system.
Instructional Manual: Equipment and Operating Data submitted prior to the testing
and startup of the equipment, subsystem, or system.
Operation and Maintenance Data: The operation and maintenance data submitted to
be included in the Operation and Maintenance Manual for the Project.
1.3ADMINISTRATIVE REQUIREMENTS
Sequencing and Scheduling
Equipment and System Data (Instructional manual):
Preliminary Data:
Do not submit until ENGINEER has approved Shop Drawings.
Submit prior to shipment date.
Final Data: Submit Instructional Manual Formatted data not less than 30 days
prior to equipment or system field functional testing. Submit Compilation
Formatted and Electronic Media Formatted data prior to Substantial Completion
of Project.
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Coordination
Where operation and maintenance documentation includes information on
installations by more than one factory-authorized service representative, assemble
and coordinate information furnished by representatives and prepare manuals.
1.4SUBMITTALS
Initial Submittal: Submit draft copy of each Operation and Maintenance Data (Manual) at
least 60 days before requesting inspection for Substantial Completion in accordance with
Division 1 Section 0131 00“Project Management and Coordination.” Include a complete
operation and maintenance directory. ENGINEER will return one copy of draft and mark
whether general scope and content of Manual is acceptable.
Final Submittal: Submit one (1) copy of each Manual in final form at least 30 days before
requesting inspection for Substantial Completion. ENGINEER will return copy with
comments within 21days of receipt or notify CONTRACTOR it’s accepted.
Correct or modify each manual to comply with ENGINEER’S comments. Submit (4)
copies of each corrected manual within 21days of receipt of ENGINEER’S comments.
Provide three (3) electronic copies of the final manual in PDF format.
PRODUCTS
2.1OPERATION AND MAINTENANCE DOCUMENTATION DIRECTORY
Organization: Include a section in the directory for each of the following:
List of documents.
List of systems.
List of equipment.
Table of contents.
List of Systems and Subsystems: List systems alphabetically or by treatment area as
directed by ENGINEER. Include references to operation and maintenance manuals that
contain information about each system.
List of Equipment: List equipment foreach system, organized alphabetically by system or by
treatment area as directed by ENGINEER. For pieces of equipment not part of system, list
alphabetically in separate list.
Tables of Contents: Include a table of contents for each emergency, operation, and
maintenance manual.
Identification: In the documentation directory and in each operation and maintenance
manual, identify each system, subsystem, and piece of equipment with same designation
used in the Contract Documents.
2.2MANUALS, GENERAL
Organization: Unless otherwise indicated, organize each manual into a separate section for
each system and subsystem, and a separate section for each piece of equipment not part of
a system. Each manual shall contain the following materials, in the order listed:
Title page.
Table of contents.
Manual contents.
Title Page: Enclose title page in transparent plastic sleeve. Include the following
information:
Subject matter included in manual.
Name and address of Project.
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Name and address of OWNER.
Name, address, and telephone number of CONTRACTOR.
Name and address of ENGINEER.
Subcontractor, Supplier, Manufacturer, Installer, or Maintenance Contractor’s name,
address, and telephone number, as appropriate.
Identify area of responsibility of each.
Provide name and telephone number of local source of supply for parts,
replacement, and service.
Cross-reference to related systems in other operation and maintenance manuals.
Table of Contents: List each product included in manual, identified by product name,
indexed to the content of the volume, and cross-referenced to Specification Section number
in Project Manual.
If operation or maintenance documentation requires more than one volume to
accommodate data, include comprehensive table of contents for all volumes in each
volume of the set.
Manual Contents: Organize into sets of manageable size. Arrange contents alphabetically
by system, subsystem, and equipment. If possible, assemble instructions for subsystems,
equipment, and components of one system into a single binder.
Binders: Heavy-duty, 3-ring, vinyl-covered, loose-leaf binders, in thickness necessary
to accommodate contents, sized to hold 8-1/2-by-11-inch paper; with clear plastic
sleeve on spine to hold label describing contents and with pockets inside covers to
hold folded oversize sheets.
If two or more binders are necessary to accommodate data of a system,
organize data in each binder into groupings by subsystem and related
components. Cross-reference other binders if necessary to provide essential
information for proper operation or maintenance of equipment or system.
Identify each binder on front and spine, with printed title "OPERATION AND
MAINTENANCE MANUAL, VOLUME NO. ___ OF ___" , Project title or name, and
subject matter of contents. Indicate volume number for multiple-volume sets.
Text: Manufacturer’s printed data, or neatly typed.
Three-hole punch data for binding and composition; arrange printing so
punched holes do not obliterate data.
Dividers: Heavy-paper dividers with plastic-covered tabs for each section. Mark each
tab to indicate contents. Include typed list of products and major components of
equipment included in the section on each divider, cross-referenced to Specification
Section number and title of Manual.
ProtectivePlastic Sleeves: Transparent plastic sleeves designed to enclose diagnostic
software diskettes for computerized electronic equipment.
Supplementary Text: Prepared on 8-1/2-by-11-inch 20-POUND MINIMUM, white
bond paper.
Drawings: Attach reinforced, punched binder tabs on drawings and bind with text.
If oversize drawings are necessary, fold drawings to same size as text pages
and use as foldouts.
If drawings are too large to be used as foldouts, fold and place drawings in
labeled envelopes and bind envelopes in rear of manual. At appropriate
locations in manual, insert typewritten pages indicating drawing titles,
descriptions of contents, and drawing locations.
Electronic Media Format:
Portable Document format (PDF)
After all preliminary data has been found to be acceptable, submit
operational and maintenance data in PDF format on CD-ROMor USB drive.
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Files to be exact duplicates of accepted preliminary data. Arrange by
specification Section number. Bookmark sections.
Files to by fully functional and viewable in most recent version of Adobe
Acrobat.
Manufacturer’s Standard Electronic Format:
2.3OPERATION MANUALS
Content: In addition to requirements in this Section, include operation data required in
individual Specification Sections and the following information:
System, subsystem, and equipment descriptions.
Performance and design criteria.
Operating standards.
Operating procedures.
Operating logs.
Wiring diagrams.
Control diagrams.
Piped system diagrams.
Precautions against improper use.
License requirements including inspection and renewal dates.
Descriptions: Include the following:
Product name and model number.
Manufacturer's name.
Equipment identification with serial number of each component.
Equipment function.
Operating characteristics.
Limiting conditions.
Performance curves.
Engineering data and tests.
Complete nomenclature and number of replacement parts.
Operating Procedures: Include the following, as applicable:
Startup procedures.
Equipment or system break-in procedures.
Routine and normal operating instructions.
Regulation and control procedures.
Instructions on stopping.
Normal shutdown instructions.
Seasonal and weekend operating instructions.
Required sequences for electric or electronic systems.
Special operating instructions and procedures.
Systems and Equipment Controls: Describe the sequence of operation, and diagram
controls as installed.
Piped Systems: Diagram piping as installed, and identifies color-coding where required for
identification.
2.4PRODUCT MAINTENANCE MANUAL
Content: Organize manual into a separate section for each product, material, and finish.
Include source information, product information, maintenance procedures, repair materials
and sources, and warranties and bonds, as described below.
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Source Information: List each product included in manual identified by product name and
arranged to match manual's table of contents. For each product, list name, address, and
telephone number of Installer or supplier and maintenance service agent, and cross-
reference Specification Section number and title in Project Manual.
Product Information: Include the following, as applicable:
Product name and model number.
Manufacturer's name.
Color, pattern, and texture.
Material and chemical composition.
Reordering information for specially manufactured products.
Maintenance Procedures: Include manufacturer's written recommendations and the
following:
Inspection procedures.
Types of cleaning agents to be used and methods of cleaning.
List of cleaning agents and methods of cleaning detrimental to product.
Schedule for routine cleaning and maintenance.
Repair instructions.
Repair Materials and Sources: Include lists of materials and local sources of materials and
related services.
Warranties and Bonds: Include copiesof warranties and bonds and lists of circumstances
and conditions that would affect validity of warranties or bonds.
Include procedures to follow and required notifications for warranty claims.
2.5SYSTEMS AND EQUIPMENT MAINTENANCE MANUAL
Content: For each system, subsystem, and piece of equipment not part of a system, include
source information, manufacturers' maintenance documentation, maintenance procedures,
maintenance and service schedules, spare parts list and source information, maintenance
service contracts, and warranty and bond information, as described below.
Source Information: List each system, subsystem, and piece of equipment included in
manual identified by product name and arranged to match manual's table of contents. For
each product, list name, address, and telephone number of Installer or supplier and
maintenance service agent, and cross-reference Specification Section number and title in
Project Manual.
Manufacturers' Maintenance Documentation: Manufacturers' maintenance documentation
including the following information for each component part or piece of equipment:
Standard printed maintenance instructions and bulletins.
Drawings, diagrams, and instructions required for maintenance, including disassembly
and component removal, replacement, and assembly.
Identification and nomenclature of parts and components.
List of items recommended to be stocked as spare parts.
Maintenance Procedures: Include the following information and items that detail essential
maintenance procedures:
Test and inspection instructions.
Troubleshooting guide.
Precautions against improper maintenance.
Disassembly; component removal, repair, and replacement; and reassembly
instructions.
Aligning, adjusting, and checking instructions.
Demonstration and training videotape, if available.
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Maintenance and Service Schedules: Include service and lubrication requirements, list of
required lubricants for equipment, and separate schedules for preventive and routine
maintenance and service with standard time allotment.
Scheduled Maintenance and Service: Tabulate actions for daily, weekly, monthly,
quarterly, semiannual, and annual frequencies.
Maintenance and Service Record: Include manufacturers' forms for recording
maintenance.
Spare Parts List and Source Information: Include lists of replacement and repair parts, with
parts identified and cross-referenced to manufacturers' maintenance documentation and
local sources of maintenance materials and related services.
Maintenance Service Contracts: If applicable, include copies of maintenance agreements
with name and telephone number of service agent.
Warranties and Bonds: Include copies of warranties and bonds and lists of circumstances
and conditions that would affect validity of warranties or bonds.
Include procedures to follow and required notifications for warranty claims.
EXECUTION
3.1MANUAL PREPARATION
Operation and Maintenance Documentation Directory: Prepare a separate manual that
provides an organized reference to emergency, operation, and maintenance manuals.
Emergency Manual: Assemble a complete set of emergency information indicating
procedures for use by emergency personnel and by Owner's operating personnel for types
of emergencies indicated.
Product Maintenance Manual: Assemble a complete set of maintenance data indicating care
and maintenance of each product, material, and finish incorporated into the Work.
Operation and Maintenance Manuals: Assemble a complete set of operation and
maintenance data indicating operation and maintenance of each system, subsystem, and
piece of equipment not part of a system.
Engage a factory-authorized service representative to assemble and prepare
information for each system, subsystem, and piece of equipment not part of a
system.
Prepare a separate manual for each system and subsystem, in the form of an
instructional manual for use by Owner's operating personnel.
Manufacturers' Data: Where manuals contain manufacturers' standard printed data, include
only sheets pertinent to product or component installed. Mark each sheet to identify each
product or component incorporated into the Work. If data include more than one item in a
tabular format, identify each item using appropriate references from the Contract
Documents. Identify data applicable to the Work and delete referencesto information not
applicable.
Prepare supplementary text if manufacturers' standard printed data are not available
and where the information is necessary for proper operation and maintenance of
equipment or systems.
Drawings: Prepare drawings supplementing manufacturers' printed data to illustrate the
relationship of component parts of equipment and systems and to illustrate control sequence
and flow diagrams. Coordinate these drawings with information contained in Record
Drawings to ensure correct illustration of completed installation.
Do not use original Project Record Documents as part of operation and maintenance
manuals.
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Comply with requirements of newly prepared Record Drawings in Section 01 78 39
“ProjectRecord Documents."
Comply with Section 0177 00 “Closeout Procedures”for schedule for submitting operation
and maintenance documentation.
Maintenance Summary:
Compile individual Maintenance Summary Form for each applicable equipment item,
respective unit or system and for components or sub-units.
Format:
Use Maintenance Summary Form include with this Section as a guide.
Use only 8-1/2 by 11-inch size paper.
Include detailed lubrication instructions and diagrams showing pints be greased or
oiled,; recommended type, grade, and temperature range of lubricants and frequency
of lubrication.
Recommended Spare Parts:
Data to be consistent with manufacturer’s Bill ofMaterials/Parts List furnished
with the Operation and Maintenance Data.
“Unit” is the unit of measure for ordering part.
“Quantity” is the number of units recommended.
“Unit Cost” is the current purchase price.
3.2DATA FOR MATERIALS AND FINSIHES
Content for Architectural Products, Applied Materials, and Finishes:
Manufacturer’s data, giving full information on products:
Catalog number, size, and composition.
Color and texture designations.
Information required for reordering special-manufactured products.
Instructions for Care and Maintenance:
Manufacturer’s recommendation for types of cleaning agents and methods.
Cautions against cleaning agents and methods that are detrimental to product.
Recommended schedule for cleaning and maintenance.
Content for Moisture Protection and Weather Exposed Products:
Manufacturer’s data, giving full information on products:
Applicable standards.
Chemical composition.
Details of installation.
Instructions for inspection, maintenance, and repair.
3.3SUPPLEMENTS
Sample forms included after “End of Section” are considered part of this Section.
Maintenance Summary Form.
END OF SECTION
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MAINTENANCE SUMMARY FORM
PROJECT: CONTRACT NO:
EQUIPMENT ITEM:
MANUFACTURER:
EQUIPMENT TAG NOS.:
WEIGHT OF INDIVIDUAL COMPONENTS (Over 100 Pounds)
NAME PLATE DATA (HP, Voltage, Speed, etc.):
Manufacturer’s Local Representative:
Name: Telephone No.
Address:
Maintenance Operation Requirements Frequency Lubricant
List briefly each maintenance operation required
and refer to specific information in manufacturer’s
List frequency of each Refer by symbol to
maintenance manual, if applicable. Also note
maintenance operation. lubricant required.
tools needed for each maintenance operation and
safety considerations.
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MAINTENANCE SUMMARY FORM (Continued)
LUBRICANT LIST
Reference Symbol Mfgr ____________ Mfgr ____________ Mfgr ____________
List symbols used in
maintenance List equivalent lubricants of several manufacturers’
requirements
RECOMMENDED SPARE PARTS FOR OWNER’S INVENTORY
Part No. Description Unit Quantity Unit Price
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SECTION 01 78 39
PROJECT RECORD DOCUMENTS
GENERAL
1.1SUMMARY
This Section includes administrative and procedural requirements for Project Record
Documents, including the following:
RecordDrawings.
Record Specifications.
Record Product Data.
1.2REFERENCES
Preselection Drawings and general provisions of the Contract, including Preselection Special
Conditions and Division 01 Specification Sections, apply to this Section.
Related Sections:
Section 01 77 00 “Closeout Procedures” for general closeout procedures.
Section 01 78 23 "Operation and Maintenance Data" for operation and maintenance
manual requirements.
Remaining Sections for specific requirements for Project Record Documents of the
Work in those Sections.
1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Record Drawings: Submit one set of marked-up Record Prints.
Record Product Data: Submit one copy of each Product Data submittal.
PRODUCTS
2.1RECORD DRAWINGS
Record Prints: CONTRACTOR shall maintain one set of blue-or black-line white prints of the
Contract Drawings and Shop Drawings.
Preparation: Mark Record Prints to show the actual installation where installation
varies from that shown originally. Require individual or entity who obtained record
data, whether individual or entity is Installer, subcontractor, or similar entity, to
prepare the marked-up Record Prints.
Give particular attention to information on concealed elements that would be
difficultto identify or measure and record later.
Record data as soon as possible after obtaining it. Record and check the
markup before enclosing concealed installations.
Mark the Contract Drawings or Shop Drawings, whichever is most capable of showing
actual physical conditions, completely and accurately. If Shop Drawings are marked,
show cross-reference on the Contract Drawings.
Mark record sets with erasable, red-colored pencil. Use other colors to distinguish
between changes for different categories of the Work at same location.
Note Construction Change Directive numbers, alternate numbers, Change Order
numbers, and similar identification, where applicable.
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Format: Identify and date each Record Drawing; include the designation "PROJECT
RECORD DRAWING" in a prominent location.
Include identification on cover sheets.
Identification: As follows:
Date.
Designation "PROJECT RECORD DRAWINGS."
Name of ENGINEER.
Name of CONTRACTOR.
2.2MISCELLANEOUS RECORD SUBMITTALS
Assemble miscellaneous records required by other Specification Sections for miscellaneous
record keeping and submittal inconnection with actual performance of the Work. Prior to
Substantial Completion, complete miscellaneous records and place in good order, properly
identified and found or filed, ready for use and reference. Miscellaneous records include, but
are not limited to, the following:
Field records on excavations and foundations.
Field records on underground construction and similar work.
Surveys showing locations and elevations of underground lines.
Invert elevations of drainage pipes.
Surveys establishing building lines and levels.
Records of equipment testing, start-up, and operation.
Certifications received in lieu of labels on bulk products.
Batch mixing and bulk delivery tickets.
Documented qualifications of installation firms.
Inspections and certification of governing agencies.
Load and performance testing.
Results of pressure testing of lines.
Final inspection and correction procedures.
EXECUTION
3.1RECORDING AND MAINTENANCE
Recording: Maintain one copy of each submittal during the construction period for Project
Record Document purposes. Post changes and modifications to Project Record Documents
as they occur; do not wait until the end of Project.
Maintenance of Record Documents and Samples: Store Record Documents and Samples in
the fieldoffice apart from the Contract Documents used for construction. Do not use Project
Record Documents for construction purposes. Maintain Record Documents in good order
and in a clean, dry, legible condition, protected from deterioration and loss. Provide access
to Project Record Documents for ENGINEER’S reference during normal working hours.
END OF SECTION
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SECTION 02 41 19
SELECTIVE DEMOLITION
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section includes the following selective demolition work when shown on the Drawings:
Demolition and removal of selected portions of building or structure.
Demolition and removal of selected site elements.
Salvage of existing items to be reusedor recycledby CONTRACTOR or OWNER.
Related Sections include the following:
Section 01 73 29,"Cutting and Patching" for cutting and patching procedures.
Section 31 10 00,"Site Clearing" for site clearing and removal of above-and below-
grade improvements.
1.3DEFINITIONS
Remove: Detach items from existing construction and legally dispose of them off-site,
unless indicated to be removed and salvaged or removed and reinstalled.
Remove and Salvage: Detach items from existing construction and deliver them to OWNER.
Remove and Reinstall: Detach items from existing construction, prepare them for reuse,
and reinstall them where indicated.
Existing to Remain: Existing items of construction that are not to be removed and that are
not otherwise indicated to be removed, removed and salvaged, or removed and reinstalled.
1.4SUBMITTALS
Schedule of Selective Demolition Activities: Indicate detailed sequence of selective
demolition and removalwork, with starting and ending dates for each activity, interruption
of utility services, use of elevator and stairs, and locations of temporary partitions and
means of egress.
Predemolition Photographs: Show existing conditions of adjoining constructionand site
improvements, including finish surfaces, which might be misconstrued as damage caused by
selective demolition operations. Comply with Section 01 32 33,"Photographic
Documentation." Submit before Work begins.
Landfill Records: Indicate receiptand acceptance of hazardous wastes by a landfill facility
licensed to accept hazardous wastes.
1.5QUALITY ASSURANCE
Demolition Firm Qualifications: An experienced firm that has specialized in demolition work
similar in material and extent to that indicated for this Project.
Refrigerant Recovery Technician Qualifications: Certified by an EPA-approved certification
program.
Regulatory Requirements: Comply with governing EPA notification regulations before
beginning selective demolition. Comply with hauling and disposal regulations of authorities
having jurisdiction.
Standards: Comply with ANSIA10.6 and NFPA241.
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Predemolition Conference: Conduct conference at Project site.
1.6PROJECT CONDITIONS
OWNER mayoccupy portions of structures or treatment unitsimmediately adjacent to
selective demolition area. Conduct selective demolition so OWNER’S operations will not be
disrupted.
OWNER will maintain conditions existing at time of inspection for bidding purpose as far as
practical.
Before selective demolition, CONTRACTOR shall coordinate with OWNER in order for OWNER
to effectively remove the portion to be demolished from service and to remove any materials
or supplies located in these areas.
Notify ENGINEER of discrepancies between existing conditions and Drawingsbefore
proceeding with selective demolition.
Hazardous Materials: It is unknown whether hazardous materials will be encountered in the
Work.
If materials suspected of containing hazardous materials are encountered, do not
disturb; immediately notify ENGINEER and OWNER. OWNER will remove hazardous
materials under a separate contract.
Storage or sale of removed items or materials on-site is not permitted.
Utility Service: Maintain existing utilities indicated to remain in service and protect them
against damage during selective demolition operations.
Maintain fire-protection facilities in service during selective demolition operations.
1.7WARRANTY
Existing Warranties: Remove, replace, patch, and repair materials and surfaces cut or
damaged during selective demolition, by methods and with materials so as not to void
existing warranties.
PRODUCTS (NOT USED)
EXECUTION
3.1EXAMINATION
Verify that utilities have been disconnected and capped.
Survey existing conditions and correlate with requirements indicated to determine extent of
selective demolition required.
Inventory and record the condition of items to be removed and reinstalled and items to be
removed and salvaged.
When unanticipated mechanical, electrical, or structural elements that conflict with intended
function or design are encountered, investigate and measure the nature and extent of
conflict. Promptly submit a written report to ENGINEER.
Survey of Existing Conditions: Record existing conditions by use of preconstruction
photographs.
Comply with requirements specified in Section 01 32 33,"Photographic
Documentation."
Perform surveys as the Work progresses to detect hazards resulting from selective
demolition activities.
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3.2UTILITYSERVICES AND MECHANICAL/ELECTRICAL SYSTEMS
Existing Services/Systems: Maintain services/systems indicated to remain and protect them
against damage during selective demolition operations.
Service/System Requirements: Locate, identify, disconnect, and seal or cap off indicated
utility services and mechanical/electrical systems serving areas to be selectively demolished.
Arrange to shut off indicated utilities with utility companies.
If services/systems are required to be removed, relocated, or abandoned, before
proceeding with selective demolition provide temporary services/systems that bypass
area of selective demolition and that maintain continuity of services/systems to other
parts of building.
Cut off pipe or conduit in walls or partitions to be removed. Cap, valve, or plug and
seal remaining portion of pipe or conduit after bypassing.
3.3PREPARATION
Site Access and Temporary Controls: Conduct selective demolition and debris-removal
operations to ensure minimum interference with roads, streets, walks, walkways, and other
adjacent occupied and used facilities.
Comply with requirements for access and protection specified in Section 01 50 00,
“Temporary Facilities and Controls.”
Temporary Facilities: Provide temporary barricades and other protection required to prevent
injury to people and damage to adjacent buildings and facilities to remain.
Temporary Shoring: Provide and maintain shoring, bracing, and structural supports as
required to preserve stability and prevent movement, settlement, or collapse of construction
and finishes to remain, and to prevent unexpected or uncontrolled movement or collapse of
construction being demolished.
3.4SELECTIVE DEMOLITION
General: Demolish and remove existing construction only to the extent required by new
construction and as indicated. Use methods required to complete the Work within
limitations of governing regulations and as follows:
Neatly cut openings and holes plumb, square, and true to dimensions required. Use
cutting methods least likely to damage construction toremain or adjoining
construction. Use hand tools or small power tools designed for sawing or grinding,
not hammering and chopping, to minimize disturbance of adjacent surfaces.
Temporarily cover openings to remain.
Cut or drill from the exposed or finished side into concealed surfaces to avoid marring
existing finished surfaces.
Do not use cutting torches until work area is cleared of flammable materials. At
concealed spaces, such as duct and pipe interiors, verify condition and contents of
hidden spacebefore starting flame-cutting operations. Maintain portable fire-
suppression devices during flame-cutting operations.
Locate selective demolition equipment and remove debris and materials so as not to
impose excessive loads on supporting walls, floors, or framing.
Dispose of demolished items and materials promptly.
Removed and Salvaged Items:
Clean salvaged items.
Pack or crate items after cleaning. Identify contents of containers.
Store items in a secure area until delivery to OWNER.
Transport items to OWNER’S storage area designated by OWNER.
Protect items from damage during transport and storage.
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Removed and Reinstalled Items:
Clean and repair items to functional condition adequate for intended reuse. Paint
equipment to match new equipment.
Pack or crate items after cleaning and repairing. Identify contents of containers.
Protect items from damage during transport and storage.
Reinstall items in locations indicated. Comply with installation requirements for new
materials and equipment. Provide connections, supports, and miscellaneous materials
necessary to make item functional for use indicated.
Existing Items to Remain: Protect construction indicated to remain against damage and
soiling during selective demolition. When permitted by ENGINEER, items may be removed
to a suitable, protected storage location during selective demolitionand cleaned and
reinstalled in their original locations after selective demolition operations are complete.
3.5HAZARDOUS MATERIALS
This Section does not address removal of hazardous materials or substances such as
asbestos or polychlorinated byphenyls (PCBs). If these materials or substances are or could
be found on-site, stop work in the area and notify the OWNER and ENGINEER.
OWNER will contract with a licensed remediation or abatement firm to determine if
dangerous materials exist in the demolition area. If they exist, the firm will proceed with the
removal.
PCBs are heavy, oil-like liquids or solids, clear to yellow in color, produced in the U.S. from
1929 to 1977; their manufacturer banned in 1979. PCBs were used as dielectric fluids in
electrical transformers, capacitors, and fluorescent light ballasts; also in adhesives and
calking compounds.
Asbestos used in many construction products was banned in 1978. In construction
completed before 1978, asbestos is typically found in four forms; as sprayed-or troweled-on
surfaces for ceilings or walls; as the thermal insulation around pipes or ducts; as fire
proofing on structural members; and in various materials, such as shingles, roofing tiles, and
gypsum board patching compounds.
3.6DISPOSAL OF DEMOLISHED MATERIALS
General: Except for items or materials indicated to be reused, salvaged, reinstalled, or
otherwise indicated to remain OWNER’S property, remove demolished materials from Project
site and legally dispose of them in an EPA-approved landfill.
Burning: Do not burn demolished materials.
Disposal: Transport demolished materials off OWNER’S property and legally dispose them.
3.7CLEANING
Clean adjacent structures and improvements of dust, dirt, and debris caused by selective
demolition operations. Return adjacent areas to condition existing before selective
demolition operations began.
END OF SECTION
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SECTION 03 00 05
CONCRETE
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Cast-in-place concrete and grout.
2. Concrete mixes, proportioning, and source quality control for concrete.
B. Related Specification Sections include but are not necessarily limited to:
1. Division 00 - Procurement and Contracting Requirements.
2. Division 01 - General Requirements.
3. Section 03 15 19 - Anchorage to Concrete.
4. Section 31 63 29 – Drilled Piers.
1.2 QUALITY ASSURANCE
A. Referenced Standards:
1. American Concrete Institute (ACI):
a. 117, Specification for Tolerances for Concrete Construction and Materials.
b. 211.1, Standard Practice for Selecting Proportions for Normal, Heavyweight and
Mass Concrete.
c. 212.3R, Chemical Admixtures for Concrete.
d. 304R, Guide for Measuring, Mixing, Transporting, and Placing Concrete.
e. 304.2R, Placing Concrete by Pumping Methods.
f. 305.1, Hot Weather Concreting.
g. 306.1, Cold Weather Concreting.
h. 318, Building Code Requirements for Structural Concrete.
i. 347, Guide to Formwork for Concrete.
j. CT-13, Concrete Terminology.
2. ASTM International (ASTM):
a. A82, Standard Specification for Steel Wire, Plain, for Concrete Reinforcement.
b. A185, Standard Specification for Steel Welded Wire Reinforcement, Plain, for
Concrete.
c. A615, Standard Specification for Deformed and Plain Carbon-Steel Bars for
Concrete Reinforcement.
d. A1064, Standard Specification for Steel Wire and Welded Wire Replacement,
Plain and Deformed, for Concrete.
e. C31, Standard Practice for Making and Curing Concrete Test Specimens in the
Field.
f. C33, Standard Specification for Concrete Aggregates.
g. C39, Standard Test Method for Compressive Strength of Cylindrical Concrete
Specimens.
h. C94/C94M, Standard Specification for Ready-Mixed Concrete.
i. C138, Standard Method of Test for Density (Unit Weight), Yield, and Air
Content (Gravimetric) of Concrete.
j. C143, Standard Test Method for Slump of Hydraulic Cement Concrete.
k. C150, Standard Specification for Portland Cement.
l. C172, Standard Practice for Sampling Freshly Mixed Concrete.
m. C173, Standard Test Method for Air Content of Freshly Mixed Concrete by the
Volumetric Method.
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n. C231, Standard Test Method for Air Content of Freshly Mixed Concrete by the
Pressure Method.
o. C260, Standard Specification for Air-Entraining Admixtures for Concrete.
p. C309, Standard Specification for Liquid Membrane-Forming Compounds for
Curing Concrete.
q. C494, Standard Specification for Chemical Admixtures for Concrete.
r. C618, Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete.
s. C1293, Standard Test Method for Determination of Length Change of Concrete
Due to Alkali-Silica Reaction.
t. C1315, Standard Specification for Liquid Membrane-Forming Compounds
Having Special Properties for Curing and Sealing Concrete.
u. D882, Standard Test Method for Tensile Properties of Thin Plastic Sheeting.
v. D994, Standard Specification for Preformed Expansion Joint Filler for Concrete
(Bituminous Type).
w. D1056, Standard Specification for Flexible Cellular Materials-Sponge or
Expanded Rubber.
x. D1709, Standard Test Methods for Impact Resistance of Plastic Film by the
Free-Falling Dart Method.
y. D1751, Standard Specification for Preformed Expansion Joint Filler for Concrete
Paving and Structural Construction (Nonextruding and Resilient Bituminous
Types).
z. E96, Standard Test Methods for Water Vapor Transmission of Materials.
aa. E329, Standard Specification for Agencies Engaged in Construction Inspection
and/or Testing.
3. Corps of Engineers (COE):
a. CRD-C621, Standard Specification for Packaged, Dry, Hydraulic-Cement Grout
(Nonshrink).
4. National Ready Mixed Concrete Association (NRMCA).
5. National Sanitation Foundation (NSF):
a. 61, Drinking Water System Components - Health Effects.
B. Quality Control:
6. Concrete testing agency:
a. Contractor to employ and pay for services of a testing laboratory to:
1) Perform materials evaluation.
2) Design concrete mixes.
b. Concrete testing agency to meet requirements of ASTM E329.
7. Do not begin concrete production until proposed concrete mix design has been
approved by Engineer.
a. Approval of concrete mix design by Engineer does not relieve Contractor of his
responsibility to provide concrete that meets the requirements of this
Specification.
8. Adjust concrete mix designs when material characteristics, job conditions, weather,
strength test results or other circumstances warrant.
a. Do not use revised concrete mixes until submitted to and approved by
Engineer.
C. Qualifications:
1. Ready mixed concrete batch plant certified by NRMCA.
1.3 DEFINITIONS
A. Per ACI CT-13 except as modified herein:
1. Concrete fill: Non-structural concrete.
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2. Concrete Testing Agency: Testing agency employed to perform materials evaluation,
design of concrete mixes or testing of concrete placed during construction.
3. Exposed concrete: Exposed to view after construction is complete.
4. Indicated: Indicated by Contract Documents.
5. Nonexposed concrete: Not exposed to view after construction is complete.
6. Required: Required by Contract Documents.
7. Specified strength: Specified compressive strength at 28 days.
8. Submitted: Submitted to Engineer.
1.4 SUBMITTALS
A. Shop Drawings:
1. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
2. Concrete mix designs proposed for use.
a. Concrete mix design submittal to include the following information:
1) Sieve analysis and source of fine and coarse aggregates.
2) Test for aggregate organic impurities.
3) Test for deleterious aggregate per ASTM C1293.
4) Proportioning of all materials.
5) Type of cement with mill certificate for cement.
6) Type of fly ash with certificate of conformance to specification
requirements.
7) Slump.
8) Air content.
9) Brand, type, ASTM designation, and quantity of each admixture
proposed for use.
10) 28-day cylinder compressive test results of trial mixes per ACI 318 and
as indicated herein.
3. Product technical data including:
a. Acknowledgement that products submitted meet requirements of standards
referenced.
b. Manufacturer's installation instructions.
c. Manufacturers and types:
1) Joint fillers.
2) Curing agents.
3) Nonshrink grout with cure/seal compound.
4. Reinforcing steel:
a. Show grade, sizes, number, configuration, spacing, location, concrete cover,
dimensions and all fabrication and placement details.
b. In sufficient detail to permit installation of reinforcing without having to make
reference to Contract Drawings.
c. Obtain approval of Shop Drawings by Engineer before fabrication.
d. Mill certificates.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Storage of Material:
1. Cement and pozzolan:
a. Store in moisture proof, weathertight enclosures.
b. Do not use if caked or lumpy.
2. Aggregate:
a. Store to prevent segregation and contamination with other sizes or foreign
materials.
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b. Obtain samples for testing from aggregates at point of batching.
c. Do not use frozen or partially frozen aggregates.
d. Do not use bottom 6 IN of stockpiles in contact with ground.
e. Allow sand to drain until moisture content is uniform prior to use.
3. Admixtures:
a. Protect from contamination, evaporation, freezing, or damage.
b. Maintain within temperature range recommended by manufacturer.
c. Completely mix solutions and suspensions prior to use.
4. Reinforcing steel: Support and store all rebars above ground.
B. Delivery:
1. Concrete:
a. Prepare a delivery ticket for each load for ready-mixed concrete.
b. Truck operator shall hand ticket to Owner's Resident Project Representative at
the time of delivery.
c. Ticket to show:
1) Mix identification mark.
2) Quantity delivered.
3) Amount of each material in batch.
4) Outdoor temp in the shade.
5) Time at which cement was added.
6) Numerical sequence of the delivery.
7) Amount of water added.
2. Reinforcing steel:
a. Ship to jobsite with attached plastic or metal tags with permanent mark
numbers.
b. Mark numbers to match Shop Drawing mark number.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following products and
manufacturers are acceptable:
1. Nonshrink, nonmetallic grout:
a. Sika "SikaGrout 212."
b. Euclid Chemial "NS Grout."
c. Master Builders Solutions "Masterflow 713."
2. Expansion joint fillers:
a. Permaglaze Co.
b. Rubatex Corp.
c. Williams Products, Inc.
3. Form coating:
a. Richmond "Rich Cote."
b. Industrial Lubricants "Nox-Crete Form Coating."
c. Euclid Chemical "Kurez DR VOX."
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2.2 MATERIALS
A. Fly Ash:
1. ASTM C618, Class F
2. Nonstaining.
a. Hardened concrete containing fly ash to be uniform light gray color.
3. Maximum loss on ignition: 6 PCT.
4. Compatible with other concrete ingredients.
B. Admixtures:
1. Air entraining admixtures: ASTM C260.
2. Water reducing, retarding, and accelerating admixtures:
a. ASTM C494 Type A through E.
b. Conform to provisions of ACI 212.3R.
c. Do not use retarding or accelerating admixtures unless specifically approved in
writing by Engineer and at no cost to Owner.
d. Follow manufacturer's instructions.
e. Use chloride free admixtures only.
3. Maximum total water-soluble chloride ion content contributed from all ingredients of
concrete including water, aggregates, cementitious materials, and admixtures by
weight percent of cement:
a. 0.10 all concrete.
4. Do not use calcium chloride.
5. Pozzolanic admixtures: ASTM C618.
6. Provide admixtures of same type, manufacturer and quantity as used in establishing
required concrete proportions in the mix design.
C. Water: Potable, clean, free of oils, acids, and organic matter.
Aggregates:
1. Normal weight concrete: ASTM C33, except as modified below.
2. Fine aggregate:
a. Clean natural sand.
b. No manufactured or artificial sand.
3. Coarse aggregate:
a. Crushed rock, natural gravel, or other inert granular material.
b. Maximum amount of clay or shale particles: 1 PCT.
4. Gradation of coarse aggregate:
a. Lean concrete and precast soil retainers: Size #7.
b. All other concrete: Size #57 or #67.
E. Concrete Grout:
1. Nonshrink, nonmetallic grout:
a. Nonmetallic, noncorrosive, nonstaining, premixed with only water to be added.
b. Grout to produce a positive but controlled expansion.
c. Mass expansion not to be created by gas liberation.
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d. Minimum compressive strength of nonshrink grout at 28 days: 6500 PSI.
e. In accordance with COE CRD-C621.
F. Reinforcing Steel:
1. Reinforcing bars: ASTM A615, Grade 60.
2. Welded wire reinforcement:
a. ASTM A185 or ASTM A1064.
b. Minimum yield strength: 60,000 PSI.
G. Forms
1. Prefabricated or job built.
2. Wood forms:
a. 5/8 or 3/4 IN 5-ply structural plywood of concrete form grade.
b. Built-in-place or prefabricated type panel.
3. Metal forms:
a. Metal forms may be used except for aluminum in contact with concrete.
b. Forms to be tight to prevent leakage, free of rust and straight without dents to
provide members of uniform thickness.
4. Chamfer strips: Clear white pine, surface against concrete planed.
H. Form Ties:
1. Commercially fabricated for use in form construction.
a. Field fabricated ties are unacceptable.
2. Constructed so that ends or end fasteners can be removed without causing spalling at
surfaces of the concrete.
3. 3/4 IN minimum to 1 IN maximum diameter cones on both ends.
4. Embedded portion of ties to be not less than 1-1/2 IN from face of concrete after
ends have been removed.
5. Cone size:
a. 3/4 IN minimum to 2 1/2 IN maximum diameter cones on both ends.
b. Depth of cone not to exceed the concrete reinforcing cover.
6. Form release: Nonstaining and shall not prevent bonding of future finishes to
concrete surface.
I. Chairs, Runners, Bolsters, Spacers, and Hangers:
1. Stainless steel, epoxy coated, or plastic-coated metal.
a. Plastic coated: Rebar support tips in contact with the forms only.
J. Membrane Curing Compound:
1. ASTM C309, Type 1D, Class B.
2. Fugitive dye shall dissipate over time and exposure.
3. Curing compound shall not prevent bonding of any future coverings, coatings, or
finishes.
K. Expansion Joint Filler:
1. In contact with water or sewage:
a. Closed cell neoprene.
b. ASTM D1056, Class SC (oil resistant and medium swell) of 2 to 5 PSI
compression deflection (Grade SCE41).
2. Exterior driveways, curbs, and sidewalks:
a. Asphalt expansion joint filler.
b. ASTM D994.
3. Other use:
a. Fiber expansion joint filler.
b. ASTM D1751.
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2.3 CONCRETE MIXES
A. General:
1. All concrete to be ready mixed concrete conforming to ASTM C94/C94M.
2. Provide concrete of specified quality capable of being placed without segregation and,
when cured, of developing all properties required.
3. All concrete to be normal weight concrete.
4. Provide pozzolan content for all cast-in-place construction.
B. Strength:
5. Provide specified strength and type of concrete for each use in structure(s) as follows:
SPECIFIED
TYPE WEIGHT STRENGTH*
General use concrete Normal weight 4000 PSI
* Minimum 28-day compressive strength.
C. Air Entrainment:
1. Provide air entrainment in all concrete resulting in a total air content percent by
volume as follows:
MAX AGGREGATE SIZE TOTAL AIR CONTENT PERCENT
1 IN or 3/4 IN 6 ±1-1/2
<3/4 IN 6-1/2 ±1-1/2
2. Air content to be measured in accordance with ASTM C231, ASTM C173, or ASTM
C138.
3. Occasional varia2ons in the air
2.3.C.1 above will not be cause for rejec2on. When the quan2ty of entrained air
6
is found to be above 7.5 percent with 1-inch or ¾-inch aggregate, or above 8
percent with aggregate smaller than ¾-inch, addi2onal test cylinders will be
made. If the cylinders pass the minimum compressive strength requirements,
the concrete will not be rejected because of the varia2on in the air content.
D. Slump - 4 IN maximum, 1 IN minimum:
1. Measured at point of discharge of the concrete into the concrete construction
member.
2. 8 IN maximum after addition of superplasticizer (if used).
3. Concrete of lower than minimum slump may be used provided it can be properly
placed and consolidated.
4. Pumped concrete:
a. Provide additional water at batch plant to allow for slump loss due to pumping.
b. Provide only enough additional water so that slump of concrete at discharge
end of pump hose does not exceed maximum slump specified and the
maximum specified water-cement ratio is not exceeded.
5. Slump may be adjusted in the field through the use of water reducers.
a. Coordinate dosage and mixing requirements with concrete supplier.
6. Determine slump per ASTM C143.
E. Selection of Proportions:
1. General:
a. Proportion ingredients to:
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0537-038-01 CONCRETE JANUARY 2023
1) Produce proper workability, durability, strength, and other required
properties.
2) Prevent segregation and collection of excessive free water on surface.
2. Minimum cement contents and maximum water cement ratios for concrete to be as
follows:
MAXIMUM WATER
MINIMUM CEMENT
SPECIFIED STRENGTH CEMENT RATIO BY
(PSI) (LBS/CY) WEIGHT
4000 564 0.45
3. Fly ash:
a. For cast-in-place concrete only, a maximum of 25 PCT by weight of Portland
cement content per cubic yard may be replaced with fly ash at rate of 1 LB fly
ash for 1 LB of cement.
b. When fly ash is used, the water to cementitious materials ratio shall not exceed
the maximum value specified herein.
4. Concrete mix proportioning methods for normal weight concrete:
a. Proportion mixture to provide desired characteristics using one of methods
described below:
1) Method 1 (Trial Mix):
a) Per ACI 301, except as modified herein.
b) Air content within range specified above.
c) Record and report temperature of trial mixes.
d) Proportion trial mixes per ACI 211.1.
2) Method 2 (Field Experience):
a) Per ACI 301, except as modified herein:
b) Field test records must be acceptable to Engineer to use this
method.
c) Test records shall represent materials, proportions, and conditions
similar to those specified.
5. Required average strength to exceed the specified 28-day compressive strength by
the amount determined or calculated in accordance with the requirements of ACI 301
using the standard deviation of the proposed concrete production facility.
PART 3 - EXECUTION
3.1 FORMING AND PLACING CONCRETE
A. Formwork:
1. Contractor is responsible for design and erection of formwork.
2. Construct formwork so that concrete members and structures are of correct size,
shape, alignment, elevation, and position.
a. Allowable tolerances: As recommended in ACI 347.
3. Openings:
a. Provide openings in formwork to accommodate work of other trades.
b. Accurately place and securely support items built into forms.
4. Chamfer strips: Place 3/4 IN chamfer strips in forms to produce 3/4 IN wide beveled
edges on permanently exposed corners of members.
5. Clean and adjust forms prior to concrete placement.
6. Tighten forms to prevent mortar leakage.
7. Coat form surfaces with form release agents prior to placing reinforcing bars in forms.
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B. Reinforcement:
1. Position, support, and secure reinforcement against displacement.
2. Locate and support with chairs, runners, bolsters, spacers, and hangers, as required.
3. Set wire ties so ends do not touch forms and are directed into concrete, not toward
exposed concrete surfaces.
4. Lap splice lengths: ACI 318 Class B top bar tension splices unless indicated otherwise
on the Drawings.
5. Extend reinforcement to within 2 IN of concrete perimeter edges unless shown
otherwise on Drawings.
a. If perimeter edge is earth formed, extend reinforcement to within 3 IN of the
edge.
6. Minimum concrete protective covering for reinforcement: As shown on Drawings.
7. Do not weld reinforcing bars.
8. Welded wire reinforcement:
a. Install welded wire reinforcement in maximum practical sizes.
b. Splice sides and ends with a splice lap length measured between outermost
cross wires of each fabric sheet not less than:
1) One spacing of cross wires plus 2 IN.
2) 1.5 x development length.
3) 6 IN.
c. Development length: ACI 318 basic development length for the specified fabric
yield strength.
C. Construction, Expansion, and Contraction Joints:
1. Locate joints as indicated on Contract Drawings or as shown on approved Shop
Drawings.
a. Where construction joint spacing shown on Drawings exceeds the joint spacing
indicated in Paragraph below, submit proposed construction joint location in
conformance with this Specification Section.
2. Unplanned construction joints will not be allowed.
3. Locate construction joints in floor slabs and foundation base slabs so that concrete
placements are approximately square and do not exceed 2500SQFT.
4. Install construction joints perpendicular to main reinforcement with all reinforcement
continued across construction joints.
5. At least 48 HRS shall elapse between placing of adjoining concrete construction.
6. Thoroughly clean and remove all laitance and loose and foreign particles from
construction joints.
7. Before new concrete is placed, dampen concrete surfaces.
D. Embedments:
1. Set and build in anchorage devices and other embedded items required for other
work that is attached to or supported by concrete.
2. See Specification Section 03 15 19 - Anchorage to Concrete.
3. Use setting diagrams, templates, and instructions for locating and setting.
E. Placing Concrete:
1. Place concrete in compliance with ACI 304R and ACI 304.2R.
2. Place in a continuous operation within planned joints or sections.
3. Begin placement when work of other trades affecting concrete is completed.
4. Place concrete by methods which prevent aggregate segregation.
5. Do not allow concrete to free fall more than 4 FT.
6. Where free fall of concrete will exceed 4 FT, place concrete by means of tremie pipe
or chute.
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F. Consolidation: Consolidate all concrete using mechanical vibrators supplemented with hand
rodding and tamping, so that concrete is worked around reinforcement and embedded items
into all parts of forms.
G. Protection:
7. Protect concrete from physical damage or reduced strength due to weather extremes.
8. In cold weather comply with ACI 306.1 except as modified herein.
a. Do not place concrete on frozen ground or in contact with forms or reinforcing
bars coated with frost, ice, or snow.
b. Do not place heated concrete that is warmer than 80 DEGF.
c. If freezing temperatures are expected during curing, maintain the concrete
temperature at or above 50 DEGF for seven days or 70 DEGF for 3 days.
d. Do not allow concrete to cool suddenly.
9. In hot weather comply with ACI 305.1 except as modified herein.
a. At air temperature of 90 DEGF and above, keep concrete as cool as possible
during placement and curing.
b. Do not allow concrete temperature to exceed 90 DEGF at placement.
c. Prevent plastic shrinkage cracking due to rapid evaporation of moisture.
d. Do not place concrete when the actual or anticipated evaporation rate equals
or exceeds 0.2 LBS/SF/HR as determined from ACI 305.1, Figure 2.1.5.
H. Curing:
10. Begin curing concrete as soon as free water has disappeared from exposed surfaces.
11. Cure concrete by use of moisture retaining cover, burlap kept continuously wet or by
membrane curing compound.
12. Provide protection as required to prevent damage to concrete and to prevent
moisture loss from concrete during curing period.
13. Provide curing for minimum of 14 days.
14. Form materials left in place may be considered as curing materials for surfaces in
contact with the form materials except in periods of hot weather.
15. In hot weather follow curing procedures outlined in ACI 305.1.
16. In cold weather follow curing procedures outlined in ACI 306.1.
17. Curing vertical surfaces with a curing compound:
a. Cover vertical surfaces with a minimum of two coats of the curing compound.
b. Allow the preceding coat to completely dry prior to applying the next coat.
c. Apply the first coat of curing compound immediately after form removal.
d. Vertical surface at the time of receiving the first coat shall be damp with no
free water on the surface.
e. A vertical surface is defined as any surface steeper than 1 vertical to 4
horizontal.
I. Form Removal:
18. Remove forms after concrete has hardened sufficiently to resist damage from removal
operations or lack of support.
19. Where no reshoring is planned, leave forms and shoring used to support concrete
until it has reached its specified 28-day compressive strength.
3.2 CONCRETE FINISHES
A. Tolerances:
1. Class A: 1/8 IN in 10 FT.
2. Class B: 1/4 IN in 10 FT.
B. Surfaces Exposed to View:
3. Provide a smooth finish for exposed concrete surfaces and surfaces that are:
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a. To be covered with a coating or covering material applied directly to concrete.
b. Scheduled for grout cleaned finish.
4. Remove fins and projections, and patch voids, air pockets, and honeycomb areas with
cement grout.
C. Surfaces Not Exposed to View:
1. Patch voids, air pockets and honeycomb areas with cement grout.
2. Fill tie holes with nonshrink, nonmetallic grout.
D. Slab Float Finish:
1. After concrete has been placed, consolidated, struck off, and leveled, do no further
work until ready for floating.
2. Do not use water to aid in finishing.
3. Begin floating when water sheen has disappeared, and surface has stiffened
sufficiently to permit operation.
4. During or after first floating, check planeness of entire surface with a 10 FT
straightedge applied at not less than two different angles.
5. Cut down all high spots and fill all low spots during this procedure to produce a
surface within Class B tolerance throughout.
6. Refloat slab immediately to a uniform sandy texture.
E. Troweled Finish:
1. Float finish surface.
2. Next power trowel, and finally hand trowel.
3. Do not use water to aid in finishing.
4. Produce a smooth surface which is relatively free of defects with firsthand troweling.
5. Perform additional trowelings by hand after surface has hardened sufficiently.
6. Final trowel when a ringing sound is produced as trowel is moved over surface.
7. Thoroughly consolidate surface by hand troweling.
8. Leave finished surface essentially free of trowel marks, uniform in texture and
appearance and plane to a Class A tolerance.
9. On surfaces intended to support floor coverings remove any defects of sufficient
magnitude that would show through floor covering by grinding.
F. Broom Finish: Immediately after concrete has received a float finish as specified, give it a
transverse scored texture by drawing a broom across surface.
3.3 GROUT
A. Preparation:
1. Nonshrinking, nonmetallic grout:
a. Clean concrete surface to receive grout.
b. Saturate concrete with water for 24 HRS prior to grouting.
B. Application:
1. Nonshrinking, nonmetallic grout:
a. Mix in a mechanical mixer.
b. Use no more water than necessary to produce flowable grout.
c. Place in accordance with manufacturer's instructions.
d. Completely fill all spaces and cavities below the bottom of baseplates.
e. Provide forms where baseplates and bedplates do not confine grout.
f. Where exposed to view, finish grout edges smooth.
g. Except where a slope is indicated on Drawings, finish edges flush at the
baseplate, bedplate, member, or piece of equipment.
h. Protect against rapid moisture loss by covering with wet rags or polyethylene
sheets.
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0537-038-01 CONCRETE JANUARY 2023
i. Wet cure grout for seven days, minimum.
3.4 FIELD QUALITY CONTROL
A. Owner will employ and pay for services of a concrete testing laboratory to perform testing of
concrete placed during construction.
1. Contractor to cooperate with Owner in obtaining and testing samples.
B. Tests During Construction:
1. Strength test:
a. For each strength test, mold and cure cylinders from each sample in
accordance with ASTM C31.
1) Cylinder size: Per ASTM C31.
a) 4 IN cylinders may not be used for concrete mixes with concrete
aggregate size larger than 1 IN.
2) Quantity:
a) 6 IN DIA by 12 IN high: Four cylinders.
b) 4 IN DIA by 8 IN high: Six cylinders.
b. Field cure one (1) cylinder for the seven-day test.
1) Laboratory cure the remaining.
c. Test cylinders in accordance with ASTM C39.
1) 6 IN DIA cylinders:
a) Test two cylinders at 28 days for strength test result and the one
field cured sample at seven days for information.
b) Hold remaining cylinder in reserve.
2) 4 IN DIA cylinders:
a) Test three cylinders at 28 days for strength test result and the one
field cured cylinder at seven days for information.
b) Hold remaining cylinders in reserve.
d. Strength test result:
1) Average of strengths of two 6 IN DIA cylinders or three 4 IN DIA
cylinders from the same sample tested at 28 days.
2) If one cylinder in a test manifests evidence of improper sampling,
molding, handling, curing, or testing, discard and test reserve
cylinder(s); average strength of remaining cylinders shall be considered
strength test result.
3) Should all cylinders in any test show any of above defects, discard entire
test.
e. Frequency of tests:
1) One strength test to be taken not less than once a day, nor less than
once for each 60 CUYD or fraction thereof placed in any one day.
2) Once for each 5000 SQFT of slab or wall surface area placed each day.
3) If total volume of concrete on Project is such that frequency of testing
required in above paragraph will provide less than five strength tests for
each concrete mix, tests shall then be made from at least five randomly
selected batches or from each batch if fewer than five batches are
provided.
2. Slump test:
a. Per ASTM C143.
b. Determined for each strength test sample.
c. Additional slump tests may be taken.
3. Air content:
a. Per ASTM C231, ASTM C173, and ASTM C138.
b. Determined for each strength test sample.
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4. Temperature: Determined for each strength test sample.
C. Evaluation of Tests:
1. Strength test results:
a. Average of 28-day strength of two cylinders from each sample.
1) If one cylinder manifests evidence of improper sampling, molding,
handling, curing, or testing, strength of remaining cylinder will be test
result.
2) If both cylinders show any of above defects, test will be discarded.
D. Acceptance of Concrete:
1. Strength level of each type of concrete shall be considered satisfactory if both of the
following requirements are met:
a. Average of all sets of three consecutive strength tests equals or exceeds the
required specified 28-day compressive strength.
b. No individual strength test falls below the required specified 28-day
compressive strength by more than 500 PSI.
2. If tests fail to indicate satisfactory strength level, perform additional tests and/or
corrective measures as directed by Engineer.
a. Perform additional tests and/or corrective measures at no additional cost to
Owner.
E. Concrete tolerances per ACI 117.
3.5 SCHEDULES
A. Form Types:
1. Surfaces exposed to view:
a. Prefabricated or job-built wood forms.
b. Laid out in a regular and uniform pattern with long dimensions vertical and
joints aligned.
c. Produce finished surfaces free from offsets, ridges, waves, and concave or
convex areas.
d. Construct forms sufficiently tight to prevent leakage of mortar.
2. Surfaces normally submerged or not normally exposed to view: Wood or steel forms
sufficiently tight to prevent leakage of mortar.
3. Other types of forms may be used:
a. For surfaces not restricted to plywood or lined forms.
b. As backing for form lining.
B. Grout:
1. Nonshrinking, nonmetallic grout: General use.
C. Concrete:
1. Precast concrete: Where indicated on Drawings.
2. Lean concrete: Where indicated on Drawings.
3. Normal weight concrete: All other concrete.
D. Concrete Finishes:
4. Slab finishes:
a. Use following finishes as applicable, unless otherwise indicated:
1) Broom finish: Sidewalks, concrete stairs, micropile caps, and exterior
equipment foundations and equipment pads.
END OF SECTION
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PAGE INTENTIONALLY LEFT BLANK
SECTION 03 15 19
ANCHORAGE TO CONCRETE
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Requirements for all cast-in-place anchor bolts, anchor rods, reinforcing anchorage
adhesive, and post-installed concrete anchors required for the Project.
2. Design of all concrete anchors not indicated on the Drawings including, but not
limited to, installation of anchors into concrete for the following structural and
nonstructural components:
a. Structural members and accessories.
b. Mechanical and electrical equipment and components.
c. Plumbing and piping.
d. All other components requiring attachment to concrete.
B. Related Specification Sections include but are not necessarily limited to:
1. Division 00 - Procurement and Contracting Requirements.
2. Division 01 - General Requirements.
3. Section 01 35 73 – Delegated Design Procedures
4. Section 03 00 05 – Concrete.
5. Section 26 05 36 - Cable Trays for Electrical Systems.
6. Section 40 05 07 – Hangers and Supports for Process Piping.
1.2 QUALITY ASSURANCE
A. Referenced Standards:
1. American Concrete Institute (ACI):
a. 318, Building Code Requirements for Structural Concrete and Commentary.
b. 355.2, Seismic Testing of Post-Installed Concrete and Masonry Anchors in
Cracked Concrete.
c. 355.4, Qualification of Post-Installed Adhesive Anchors in Concrete.
d. 350, Code Requirements for Environmental Engineering Concrete Structures
and Commentary.
2. American Concrete Institute/Concrete Reinforcing Steel Institute (ACI-CRSI):
a. Adhesive Anchor Installation Certification Program: Adhesive Anchor Installer.
3. American Institute of Steel Construction (AISC):
a. 303, Code of Standard Practice for Steel Buildings and Bridges.
4. ASTM International (ASTM):
a. A36, Standard Specification for Carbon Structural Steel.
b. A108, Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished.
c. A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron
and Steel Products.
d. A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware.
e. A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI
Tensile Strength.
f. A496, Standard Specification for Steel Wire, Deformed, for Concrete
Reinforcement.
g. A563, Standard Specification for Carbon and Alloy Steel Nuts.
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h. A780, Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip
Galvanized Coatings.
i. F436, Standard Specification for Hardened Steel Washers.
j. F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and
Studs.
k. F594, Standard Specification for Stainless Steel Nuts.
l. F1554, Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield
Strength.
m. F2329, Standard Specification for Zinc Coating, Hot-Dip, Requirements for
Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special
Threaded Fasteners
5. ICC Evaluation Service (ICC-ES):
a. AC193, Acceptance Criteria for Mechanical Anchors in Concrete Elements.
b. AC308, Acceptance Criteria for Post-Installed Adhesive Anchors in Concrete
Elements.
B. Qualifications:
1. Anchor designer for Contractor-designed post-installed anchors and cast in place
anchorage shall be a professional civil engineer licensed in the State that the Project
is located in.
2. Installer for post-installed anchors shall be trained by the manufacturer or certified by
a training program approved by the Engineer.
3. Installer for adhesive anchors installed in horizontal, upward incline, or overhead
applications shall be certified by ACI-CRSI Adhesive Anchor Installation Certification
Program.
C. Post-installed anchors and related materials shall be listed by the following agencies:
1. ICC-ES.
2. Engineer approved equivalent.
1.3 DEFINITIONS
A. Adhesive Anchors:
1. Post-installed anchors developing their strength primarily from chemical bond
between the concrete and the anchor.
2. Includes anchors using acrylics, epoxy, and other similar adhesives.
B. Anchor Bolt: Any cast-in-place anchorage that is made of a headed (i.e. bolt) material.
C. Anchor Rod: Any cast-in-place or post-installed anchorage made from unheaded, threaded,
rod or deformed bar material.
D. Concrete Anchor: Generic term for either an anchor bolt or an anchor rod.
E. Galvanizing: Hot-dip galvanizing per ASTM A123, ASTM A153 or ASTM F2329 with minimum
coating of 2.0 OZ of zinc per square foot of metal (average of specimens) unless noted
otherwise or dictated by standard.
F. Hardware: As defined in ASTM A153.
G. Installer or Applicator:
1. Installer or applicator is the person actually installing or applying the product in the
field at the Project site.
2. Installer and applicator are synonymous.
H. MPII: Manufacturer’s printed installation instructions.
I. Mechanical Anchors:
1. Post-installed anchors developing their strength from attachment other than through
adhesives or chemical bond to concrete.
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2. Includes expansion anchors, expansion sleeve, screw anchors, undercut anchors,
specialty inserts and other similar types of anchorages.
3. Drop-in anchors and other similar non-ICC ES approved anchors are not allowed.
J. Post-Installed Anchor: Any adhesive or mechanical anchor installed into previously placed
and adequately cured concrete.
1.4 SUBMITTALS
A. Shop Drawings:
1. Product technical data including:
a. Acknowledgement that submitted products meet requirements of referenced
standards.
b. Manufacturer material data sheet for each anchor.
1) Clearly indicate which products on the data sheet are proposed for use
on the Project.
c. Manufacturer's printed installation instructions.
d. Current ICC-ES report for each post-installed anchor system indicating the
following:
1) Certification that anchors meet all requirements indicated in this
Specification.
2) Performance data showing that anchor is approved for use in cracked
concrete.
3) Seismic design categories for which anchor system has been approved.
4) Required installation procedures.
5) Special inspection requirements for installation.
e. Anchorage layout drawings and details:
1) Indicate anchor diameter, embedment, length, anchor type, material,
and finish.
2) Drawings showing location, configuration, spacing and edge distance.
f. Contractor Designed Post-Installed Anchors:
1) Show diameter and embedment depth of each anchor.
2) Indicate compliance with ACI 350 Appendix D.
3) Design tension and shear loads used for anchor design.
4) Engineering design calculations:
a) Indicate design load to each anchor.
b) When the design load is not indicated on Drawings, include
calculations to develop anchor forces based on Design Criteria
listed herein.
c) Sealed and signed by contractor’s professional \[structural\]
engineer.
d) Calculations will be submitted for information purposes only.
5) Type of post-installed anchor system used.
a) Provide manufacturer's ICC-ES report for the following:
(1) Mechanical anchorage per ICC-ES AC193.
(2) Adhesive anchorage per ICC-ES AC308.
B. Samples:
1. Representative samples of concrete anchors may be requested by Engineer. Review
will be for type and finish only. Compliance with all other requirements is exclusively
the responsibility of the Contractor.
C. Informational Submittals:
1. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
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2. Certification of qualifications for each installer of post-installed anchors.
a. Indicate successful completion or certification for each type of approved post-
installed anchor as required by the Contract Documents.
b. Provide one of the following for each type of anchor, as required by this
specification section:
1) Letter from manufacturer documenting successful training completion.
2) Certification of completion for Engineer approved program.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver products to job site in manufacturer’s or distributor’s packaging undamaged and
complete with installation instructions.
B. Store above ground on skids or other supports to keep items free of dirt and other foreign
debris and to protect against corrosion.
C. Protect and handle materials in accordance with manufacturer’s recommendations to
prevent damage or deterioration.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Cast-in-place Concrete Anchors:
1. Building, nonbuilding structures, and equipment, unless otherwise specified:
a. ASTM F1554, Grade 36 or Grade 55 with weldability supplement S1 for
galvanized or non-galvanized threaded rods.
b. ASTM A307, Grade A for galvanized headed bolts.
2. All other cast-in-place concrete anchors:
a. Stainless steel with matching nut and washer.
b. Non-submerged application: ASTM F593, Type 316.
B. Post-Installed Mechanical and Adhesive Concrete Anchors:
1. Stainless steel with matching nut and washer.
2. Submerged application: ASTM F593, Type 316.
3. Non-submerged application: ASTM F593, Type 316.
C. Reinforcement: See Section 03 00 05.
D. Washers:
1. ASTM F436 unless noted otherwise, finish to match bolt.
2. If stainless steel anchorage is being used for cast-in-place anchorage, furnish washers
of the same material and alloy as in the accompanying anchorage.
3. Plate washers: Minimum 1/2 IN thick fabricated ASTM A36 square plates as specified
or required.
4. Follow manufacturer’s requirements for all post-installed anchorage.
E. Nuts:
1. ASTM A563 for all cast-in-place anchorage.
2. If stainless steel anchorage is being used for cast-in-place anchorage, nuts shall meet
ASTM F594 and be the matching material and alloy as in the accompanying
anchorage.
3. Follow manufacturer’s requirements if using post-installed anchorage.
F. Galvanizing Repair Paint:
1. High zinc dust content paint for regalvanizing welds and abrasions.
2. ASTM A780.
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3. Zinc content: Minimum 92 PCT in dry film.
4. ZRC "ZRC Cold Galvanizing" or Clearco "High Performance Zinc Spray."
G. Dissimilar Materials Protection: See Specification Section 09 91 00.
2.2 CONTRACTOR DESIGNED ANCHORAGE
A. Manufacturers:
1. Post-installed anchor systems for the listed manufacturers will be considered only if a
current ICC-ES evaluation report is submitted in accordance with the SUBMITTALS
Article in PART 1 of this Specification Section and if the anchor system is approved by
the Engineer.
a. Hilti.
b. Dewalt.
c. Simpson Strong-Tie.
2. Submit request for substitution in accordance with Specification Section 01 60 00.
B. Design the anchorage when any of the following occur:
1. Design load for concrete anchorage is shown on the Drawings.
2. When specifically required by the Contract Documents.
3. When an anchorage is required but not specified in the Drawings.
4. When anchorage is shown on Drawings other than Structural Drawings.
C. Anchorage Design Loads:
1. Determine all of the design loads, including wind and seismic loads, per the building
code.
a. Anchorage of equipment and non-structural components: Use the actual dead
and operating loads provided by the manufacturer.
b. Additional support requirements for utilities: See appropriate Specification
Section.
c. Cable tray supports: See additional requirements in Specification Section 26 05
36.
d. Pipe hangers and pipe support steel: See additional requirements listed in
Specification Section 40 05 07.
D. When Contract Drawings, other than the Structural Drawings, indicate an anchor diameter
or length, the Contractor design shall incorporate these as “minimums.”
E. Cast-in-Place Concrete Anchors:
1. Provide the material, nominal diameter, embedment length, spacing, edge distance
and design capacity to resist the calculated load based on the requirements given in
the building code including ACI 350, Appendix D.
2. Design assuming cracked concrete.
F. Post-installed Concrete Anchors:
1. Provide the manufacturer’s system name/type, nominal diameter, embedment depth,
spacing, minimum edge distance, cover, and design capacity to resist the specified or
calculated load based on requirements given in the building code, ACI 350, Appendix
D and current ICC-ES report, for the anchor to be used.
2. Design assuming cracked concrete.
2.3 ENGINEER DESIGNED ANCHORAGE
A. When the size, length and details of anchorages are shown on Contract Structural Drawings,
Contractor design of anchorage is not required unless otherwise indicated.
B. Manufacturers:
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1. Additional newer post-installed anchor systems for the listed manufacturers will be
considered only if a current evaluation agency report is submitted in accordance with
the SUBMITTALS Article in PART 1 of this Specification Section, the anchor system is
certified by ICC-ES for cracked concrete conditions, and if approved by the Engineer.
2. Mechanical Anchors:
a. Hilti:
1) Kwik Bolt TZ (ICC-ES ESR-1917).
3. Adhesive Concrete Anchors:
a. Hilti:
1) HIT-RE 500 V3 (ICC ESR-3814).
4. Concrete Screw Anchors:
a. Hilti:
1) Kwik HUS-EZ Screw (ICC-ES ESR-3027).
5. Submit request for substitution in accordance with Specification Section 01 60 00.
a. Substitution request to indicate the proposed anchor has the at least the same
tension and shear strength as the specified anchor installed as indicated in the
Contract Drawings.
b. Calculations to be stamped by a Professional Engineer registered in the state
that the Project is located in.
PART 3 - EXECUTION
3.1 GENERAL
A. Cast-in-Place Anchorage:
1. Use where anchor rods or bolts are indicated on the Drawings unless another anchor
type is approved by the Engineer.
2. Provide concrete anchorage as shown on the Drawings or as required to secure
components to concrete.
B. Adhesive Anchorage:
1. Use only where specifically indicated on the Drawings or when approved for use by
the Engineer.
2. May be used where subjected to vibration or where buried or submerged.
3. Do not use in overhead applications or sustained tension loading conditions such as
utility hangers.
4. Contact Engineer for approval when anchors will not be installed in compliance with
MPII.
C. Mechanical Anchorage:
1. Use only where specifically indicated on the Drawings or when approved for use by
the Engineer.
2. Do not use where subjected to vibration.
3. May be used in overhead applications.
4. Contact Engineer for clarification when anchors will not be installed in compliance
with manufacturer's printed installation requirements.
D. Do not use powder actuated fasteners and other types of bolts and fasteners not specified
herein for structural applications unless approved by the Engineer or specified in Contract
Documents.
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3.2 PREPARATION
A. Provide adequate time to allow for proper installation and inspection prior to placing concrete
for cast-in-place concrete anchorage.
B. Prior to installation, inspect and verify areas and conditions under which concrete anchorage is
to be installed.
1. Notify Engineer of conditions detrimental to proper and timely completion of work.
2. Do not proceed with work until unsatisfactory conditions have been corrected in a
manner acceptable to the Engineer.
C. Special Inspection is required in accordance with the building code for all concrete anchorage.
1. Notify the Special Inspector that an inspection is required prior to concrete placement
(or during post-installed anchorage installation).
2. See the FIELD QUALITY CONTROL Article in PART 3 of this Specification Section for
additional requirements.
D. Post-installed anchor manufacturer’s representative shall demonstrate and observe the proper
installation procedures for the post-installed anchors at no additional expense to the Owner.
1. Follow such procedures to assure acceptable installation.
2. Adhesive anchors must be installed in concrete aged a minimum of 21 days.
3.3 INSTALLATION
A. Tie cast-in-place anchorage in position to embedded reinforcing steel using wire.
1. Tack welding of anchorage is prohibited.
2. Chase threads as required and coat the projected portion of carbon steel anchors and
nut threads with a heavy coat of clean grease after concrete has cured.
3. Anchorage location tolerance shall be in accordance with AISC 303.
4. Provide steel or durable wood templates for all column and equipment anchorage.
a. Templates to be placed above top of concrete and not impede proper concrete
placement and consolidation.
B. Unless noted or specified otherwise:
1. Connect aluminum and steel members to concrete using stainless steel cast-in-place
anchorage unless shown otherwise.
a. Provide dissimilar materials protection per Specification Section 09 91 00.
2. Provide washers for all anchorage.
3. Where exposed, extend threaded anchorage a maximum of 3/4 IN and a minimum of
1/2 IN above the top of the fully engaged nut.
a. If anchorage is cut off to the required maximum height, threads must be
dressed to allow nuts to be removed without damage to the nuts.
C. Do the following after nuts are snug tightened down:
1. If using post-installed anchorage, follow MPII.
2. Upset threads of anchorage to prevent nuts from backing off.
a. Provide double nut or lock nut in lieu of upset threads for items that may
require removal in the future.
3. For all other cast-in-place anchorage material, tighten nuts down an additional 1/8
turn beyond snug tight to prevent nuts from backing off.
4. If two nuts are used per concrete anchor above the base plate, tighten the top nut an
additional 1/8 turn to "lock" the two nuts together.
5. If using post-installed anchorage, follow MPII.
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D. Assure that embedded items are protected from damage and are not filled in with concrete.
E. Secure architectural components such that it will not be aesthetically distorted, and fasteners
will not be overstressed from expansion, contraction, or installation.
F. Coat aluminum surfaces in contact with dissimilar materials in accordance with Specification
Section 09 91 00.
G. Repair damaged galvanized surfaces in accordance with ASTM A780.
1. Prepare damaged surfaces by abrasive blasting or power sanding.
2. Apply galvanizing repair paint to minimum 6 mils DFT in accordance with
manufacturer's instructions and ASTM A780.
H. For post-installed anchors, comply with the MPII on the hole diameter and depth required to
fully develop the tensile strength of the anchor or reinforcing bar.
1. Use hammer drills to create holes.
2. Properly clean out the hole per the ICC-ES reports utilizing a non-metallic fiber bristle
brush and compressed air or as otherwise required to remove all loose material from
the hole prior to installing the anchor in the presence of the Special Inspector.
3.4 FIELD QUALITY CONTROL
A. Special Inspection:
1. See Section 03 00 05.
B. Field Inspection and Testing
1. Owner reserves the right to inspect and test completed anchorage at a minimum of
10% (for large quantity) to 25% (smaller quantity) to 100% (very small project
quantity).
2. Such testing shall conform to requirements of ACI 355.2 and/or ACI 355.4 as
applicable.
3. Failed anchors shall be satisfactorily replaced at no cost to Owner.
3.5 CLEANING
A. After concrete has been placed, remove protection, and clean all anchorage of all concrete, dirt,
and other foreign matter.
B. Provide surface acceptable to receive field applied paint coatings when specified in Specification
Section 09 91 00.
END OF SECTION
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SECTION 05 05 23
METAL FASTENINGSAND ANCHOR BOLTS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, includingGeneral and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section Includes:
The General Contractor will supply all equipment anchor bolts, as specified in this
Section. Anchor bolts will be sized by EQUIPMENT SUPPLIER. This applies to all
equipmentspecifications. Provide anchor bolts, expansion anchors and concrete
inserts for equipment and metal fabrications as specified or shown on the Plans,
including, but not limited to:
Baffles, weirs and troughs.
Sluice and slide gates.
Hangers and brackets.
Equipment.
Piping.
Tanks.
Grating and floor plate.
Electrical, Plumbing and HVAC Work.
Wood and plastic fabrications.
Partitions and ceilings.
1.3REFERENCES AND DEFINITIONS
References:
ASTM International (ASTM):
A 36 –Specification for Carbon Structural Steel
A 193 –Specification for Alloy-Steel and Stainless Steel Bolting Materials for
High Temperature or High Pressure Service and Other Special Purpose
Applications
A 194 –Specification for Carbon and Alloy Steel for Bolts for High Pressure or
High Temperature, or Both
A 283 –Specification for Low and Intermediate Tensile Strength Carbon Steel
Plates
A 307 –Specification for Carbon Steel Externally and Internally Threaded
Standard Fasteners
A 320 –Specification for Alloy-Steel and Stainless Steel Bolting Materials for
Low-Temperature Service
C 881 –Specification for Epoxy-Resin-Base Bonding Systems for concrete
E 488 –Test Method for Strength of Anchors in Concrete and Masonry Units
E 1512 –Test Method for Testing bond Performance of Bonded Anchors
F 436 –Specification for Hardened Steel Washers
F 593 –Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs
F 594 –Specification for Stainless Steel Nuts
F 844 -Specification for Washers,Steel, Plain (Flat), Unhardened for General
Use
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F 1554 –Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield
Strength
International Code Council (ICC): Evaluation Reports for Concrete and Masonry
Anchors.
FM Global (Formerly: FM -Factory Mutual System)
NSF International (NSF)
Definitions:
Exterior Area: Location not protected from the weather by a building or other
enclosed structure.
Interior Dry Area: Location inside building or structure where floor is not subject to
liquid spills or washdown, nowherewall or roof slab is common to a water-holding or
earth-retaining structure.
Interior Wet Area: Location inside building or structurewhere floor is sloped to floor
drains or gutters and is subject to liquid spills or washdown, or where wall, floor, or
roof slab is common to a water-holding or earth-retaining structure.
Submerged: Location at or below top of wall or embankment of open water-holding
structure, such as a basin or channel, or wall, ceiling, or floor surface inside a covered
water-holding structure, or exterior below grade wall or roof surface of water-holding
structure, open or covered.
1.4SYSTEMDESCRIPTION
Design Requirements:
When the size, length or load carrying capacity of an anchor bolt, expansion anchor,
or concrete insert is not shown on the Plans, provide the size, length and capacity
required to carry the design load times a minimum safety factor of four.
Determine design loads as follows:
For equipment anchors, use the design load recommended by the
manufacturer and approved by the ENGINEER.
For pipe hangers and supports, use one half the total weight of pipe, fittings,
valves, accessories and water contained in pipe, between the hanger or
support in question and adjacent hangers and supports on both sides.
Allowances for vibration are included in the safety factor specified above.
1.5SUBMITTALS
Product Data: For each type of product indicated. Include construction details, material
descriptions, dimensions of individual components and profiles, and finishes for products.
Shop Drawings: Submit the following;
Setting drawings and templates for location and installation of anchorage devices.
Copies of manufacturer's specifications, materials, load tables, dimension diagrams
and installation instructions for anchorage devices.
Samples: Submit the following:
Representative samples of bolts, anchors and inserts as may be requested for review
by the ENGINEER. Review will be for type and finish only. Compliance with all other
requirements is the exclusive responsibility of CONTRACTOR.
1.6QUALITY ASSURANCE
Installer Qualifications: Adhesive anchor installers shall be trained and certified by
manufacturer.
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Testing Agency Qualifications: Qualified for testing anchors in accordance with ASTM E 488
and E1512.
PRODUCTS
2.1GENERAL
Unless otherwise indicated, comply with the following requirements:
ItemASTM Reference
Stainless Steel:
Bolts, Threaded Rods, and Anchor F 593, AISI Type 316, Condition CW
Studs
NutsF 594, AISI Type 316, Condition CW
Steel Bolts and Nuts:
Carbon SteelA 307 bolts, with A 563 nuts
High-StrengthA 325, Type 1 bolts, with A 563 nuts
Anchors Bolts and RodsF 1554, Grade 55, with weldability
supplement S1
EyeboltsA 489
Threaded RodsA 36
Flat Washers (Unhardened)F 844
Flat and Beveled Washers F 436
(Hardened)
Thrust Ties for Steel Pipe:
Threaded RodsA 193, Grade B7
NutsA 194, Grade 2H
PlateA 283, Grade D
Bolt, Washers, and Nuts: Use stainless steel, hot-dip galvanized steel, and zinc-plated steel
types as indicated in Fastener Schedule at end of this Section.
2.2ANCHOR BOLTS AND ANCHOR BOLT SLEEVES
Cast-In-Place Anchor Bolts:
Headed type, unless otherwise shown on Drawings.
Material type and protective coating as listed in Fastener Schedule.
Anchor Bolt Sleeves:
Plastic:
Single unit construction with corrugated sleeve.
Top of sleeve shall be self-threading to provide adjustment of threaded anchor
bolt projection.
Material: High density polyethylene.
Fabricated Steel: ASTM A 36.
2.3CONCRETE AND MASONRY DRILLED ANCHORS
MechanicalExpansion Anchors:
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Design Requirements: Anchor bolt and sleeve assembly shall have capability to
sustain without failure, a load equal to six times the load imposed when installed in
unit masonry and four times the load imposed when installed in concrete, as
determined by testing in accordance with ASTM E 488.
Material: AISI Type 316 stainless, hot-dip galvanized or zinc-plated steel as listed in
Fastener Schedule.
Current evaluation and acceptance reports by ICC or other similar code organization,
and listed by UL and FM Global.
Acceptable for use in potable water structures by NSF and local health organizations.
Type:
Self-drilling Anchors; snap-off or flush type, zinc-plated.
Non-drilling Anchors; flush type for use with zinc-plated or stainless steel bolt,
or stud type with projecting threaded stud.
Size: As shown on Drawings and required for the concrete strength specified.
Manufacturers. Subject to compliance with requirements, available products that may
be incorporated into the Work include, but are not limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Rawl, New Rochelle, NY
Simpson Strong-Tie Co., Inc., Pleasanton, CA
Wedge Anchors:
Material: AISI Type 316 stainless, hot-dip galvanized or zinc-plated steel as listed in
Fastener Schedule.
Current evaluation and acceptance reports by ICC or other similar code organization,
and listed by UL and FM Global.
Manufacturers. Subject to compliance with requirements, available products that may
be incorporated into the Work include, but are not limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Rawl, New Rochelle, NY
Simpson Strong-Tie Co., Inc., Pleasanton, CA
Adhesive Anchors:
General: Consist of all-thread anchor rod, nut, washer, and adhesive material.
Threaded rod:
Material: Unless otherwise specified:
ASTMA36 for interior application, unless otherwise specified.
ASTM F 593 Stainless steel threaded rod for exterior, interior wet, and
submerge applications.
ASTM A 193, Grade B7, Type 2 for high strength applications.
Diameter as shown on the Drawings or as required for the loads and
conditions.
Length asrequired to provide minimum depth of embedment.
Clean and free of grease, oil, or other deleterious material.
For hollow-unit masonry, provide galvanized or stainless steel wire cloth screen
tube to fit threaded rod.
Anchor rods shall have rolled threads.
Adhesive:
Two-component, designed to be used in adverse/thaw environments, with gray
color mixing.
Cure Temperature, Pot Life, and Workability: Compatible for the
intended use and environmental conditions.
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Nonsag, with selected viscosity base on installation temperature and
overhead application where applicable.
Meets ASTM C881, Type IV, Grade 3, Class A, B, and C, with the
exception of gel time and epoxy content.
Manufacturers: Subject to compliance with requirements, available
products that may be incorporated into the Work include, but are not
limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Rawl, New Rochelle, NY
Simpson Strong-Tie Co., Inc., Pleasanton, CA
Concrete Inserts:
For piping, grating and floor plate provide malleable iron inserts.
Provide those recommended by the manufacturer for the required loading.
Finish shall be black.
Powder actuated fasteners and other types of bolts and fasteners not specified herein shall
not be used unless approved by ENGINEER.
EXECUTION
3.1CAST-IN-PLACE ANCHOR BOLTS
Accurately locate and hold anchor bolts in place with templates at the time concrete is
placed.
Use anchor bolt sleeves for location adjustment and provide two nuts and one washer per
bolt of same material as bolt.
Minimum Bolt Size: 1/2-inch diameter by 12 inches long, unless otherwise shown.
3.2CONCRETE AND MASONRY DRILLED ANCHORS
Begin installation only after concrete or masonry to receive anchors has obtained design
strength.
Install in accordance with manufacturer’s instructions.
Provide minimum embedment, edge distance, and spacing as follows, unless indicated
otherwise by manufacturer’s instructions or shown otherwise on Drawings.
Min. EmbedmentMin. Edge DistanceMin. Spacing
Anchor Type(bolt diameters)(bolt diameters)(bolt diameters)
Wedge9612
Expansion
4612
and Sleeve
Adhesive9913.5
Use only drill type, bit type, and diameter recommended by anchor manufacturer. Clean
hole of debris and dust with brush and oil-free compressed air.
CONTRACTORshall accurately locate steel reinforcement by the use of a pachometer or
other approved means, prior to drilling the hole. If reinforcing is encountered in drilling holes
for mechanical anchors, the hole should be abandonedand a new hole should be drilled.
Mechanical anchors shall be set by applying the manufacturer’s recommended torque.
Adhesive Anchors:
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Do not install adhesive anchors when temperature is below 40 degreeF or above 100
degreeF.
Remove any standing water from hole with oil-free compressed air. Inside surface of
hole shall be dry.
For hollow-unit masonry, install screen tube in accordance with manufacturer’s
instructions.
Do not disturb anchor during recommended curing time.
Do not exceed maximum torque as specified in manufacturer’s instructions.
3.3FIELD QUALITY CONTROL
Testing Agency: Owner will engage a qualified testing agency to perform tests and
inspections on concrete and masonry anchors when indicated on the Drawings.
3.4MANUFACTURER’S SERVICES
Adhesive Anchors: Conduct site training of installation personnel for proper installation,
handling, and storage of adhesive anchor system.
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3.5FASTENER SCHEDULE
Unless otherwise indicated on the Drawings, provide anchor bolts and anchors as follows:
Service Use and
LocationProductRemarks
1. Anchor Bolts Cast into Concrete for Equipment Bases
Interior Dry AreasStainless steel headed anchor
bolts, unless otherwise specified
with equipment.
Submerged, Exterior, Stainless steel headed anchor See Section 09 91 00, Painting
Interior Wet, and bolts with fusion bonded coating, and Protective Coatings
Corrosive Areas unless otherwise specified with
equipment
2. Drilled Anchors for Equipment and Components to Cast-in-Place Concrete
Interior Dry AreasAdhesive stainless steel anchors
Submerged, Exterior, Adhesive stainless steel anchors
Interior Wet, and
Corrosive Areas
3. Anchors in Grout-Filled Concrete Masonry Units
Exterior and Interior Wet Adhesive stainless steel anchors
and Dry Areas
4. Anchors in Hollow Concrete Masonry Units
Exterior and Interior Wet Stainless steel adhesive anchors
and Dry Areaswith screen tube.
5. Connections for Structural Steel Framing and Support Components
Exterior and Interior Wet High-strength steel bolted Use hot-dipped galvanized
and Dry Areasconnectionshigh-strength bolted
connections for galvanized
steel framing members.
6. Connections of Aluminum Components
Submerged, Exterior and Stainless steel bolted connections,
Interior Wet and Dry unless otherwise specified with
Areasequipment.
Anti-seizing Lubricant: Use on all stainless steel threads.
Do not use adhesive anchors to support fire-resistive construction or where ambient
temperature will exceed 110°F.
END OF SECTION
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SECTION 05 12 00
STRUCTURAL STEEL
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Structural steel, including the fabrication and erection of support and bracing
members, including connections.
B. Related Specification Sections include but are not necessarily limited to:
1. Division 00 - Procurement and Contracting Requirements.
2. Division 01 - General Requirements.
3. Section 03 15 19 - Anchorage to Concrete.
1.2 QUALITY ASSURANCE
A. Reference Standards:
1. American Institute of Steel Construction (AISC):
a. 303, Code of Standard Practice for Steel Buildings and Bridges.
b. 360, Specifications for Structural Steel Buildings.
c. Quality Certification Program for Fabricators.
2. American Society of Mechanical Engineers (ASME):
a. B18.21.1, Washers: Helical Spring-Lock, Tooth Lock, and Plain
Washers (Inch Series).
3. ASTM International (ASTM):
a. A2, Standard Specification for Carbon Steel Girder Rails of Plain,
Grooved, and Guard Types.
b. A6/A6M, Standard Specification for General Requirements for Rolled
Structural Steel Bars, Plates, Shapes, and Sheet Piling.
c. A36/A36M, Standard Specification for Carbon Structural Steel.
d. A53/A53M, Standard Specification for Pipe, Steel, Black and Hot-
Dipped, Zinc-Coated, Welded and Seamless.
e. A108, Standard Specification for Steel Bar, Carbon and Alloy, Cold-
Finished.
f. A123/A123M, Standard Specification for Zinc (Hot-Dip Galvanized)
Coatings on Iron and Steel Products.
g. A153/A153M, Standard Specification for Zinc Coating (Hot-Dip) on Iron
and Steel Hardware.
h. A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000
PSI Tensile Strength.
i. A563, Standard Specification for Carbon and Alloy Steel Nuts.
j. F436, Standard Specification for Hardened Steel Washers.
k. F1554, Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-
ksi Yield Strength.
4. American Welding Society (AWS):
a. A5.1/A5.1M, Specification for Carbon Steel Electrodes for Shielded
Metal Arc Welding.
b. A5.5/A5.5M, Specification for Low-Alloy Steel Electrodes for Shielded
Metal Arc Welding.
c. A5.17/A5.17M, Specification for Carbon Steel Electrodes and Fluxes for
Submerged Arc Welding.
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d. A5.18/A5.18M, Specification for Carbon Steel Electrodes and Rods for
Gas Shielded Arc Welding.
e. A5.20/A5.20M, Specification for Carbon Steel Electrodes for Flux Cored
Arc Welding.
f. A5.23/A5.23M, Specification for Low-Alloy Steel Electrodes and Fluxes
for Submerged Arc Welding.
g. A5.28/A5.28M, Specification for Low-Alloy Steel Electrodes and Rods
for Gas Shielded Arc Welding.
h. A5.29/A5.29M, Specification for Low-Alloy Steel Electrodes for Flux
Cored Arc Welding.
i. D1.1/D1.1M, Structural Welding Code - Steel.
1) Steel stud connectors and their installation to comply with
requirements of AWS D1.1/D1.1M.
5. National Institute of Steel Detailing (NISD).
6. Research Council on Structural Connections (RCSC):
a. Specification for Structural Joints Using High-Strength Bolts.
B. Qualifications:
1. Steel fabricator:
a. Minimum of 10 years of experience in fabrication of structural steel or
participate in the AISC Certification program and is designated an AISC
Certified Plant, Category BU (formally known as STD), SB at time of
bid.
b. Fabricator plant quality control and inspection program: Meet
requirements of the building code and/or be an Approved Fabricator.
c. Plants that are not an Approved Fabricator may be acceptable,
provided:
1) Plant meets all remaining qualifications.
2. Steel erector:
a. Minimum of 10 years of experience in erection of structural steel similar
in the scope of this project or certified as CSE under the AISC Quality
Certification Program.
b. With an active and enforced quality assurance program in place, as
described in the applicable Codes.
3. Qualify welding procedures and welding operators in accordance with AWS.
1.3 DEFINITIONS
A. Owner: May mean the Owner's Designated Representative for Construction as
defined by the AISC 303.
B. Galvanizing: Hot-dipped galvanizing per ASTM A153/A153M and/or ASTM
A123/A123M with minimum coating of 2.0 OZ of zinc per square foot of metal
(average of specimens) unless noted otherwise or dictated by aforementioned
standards.
C. Approved Fabricator: Approved by the Building Official to perform the building code
required Special Inspections.
1.4 SUBMITTALS
A. Shop Drawings:
1. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
2. Product technical data including:
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a. Acknowledgement that products submitted meet requirements of
standards referenced.
b. Manufacturer's installation instructions.
c. Detailed supplemental specification relating to load indicator washers
or high-strength bolts.
1) Alternate design for Engineer approval (submitted at
Contractor's option if desired by Contractor for use).
d. Source and certification of quality for high-strength bolts, nuts, and
washers.
3. Fabrication and/or layout drawings:
a. Prepare Shop Drawings under NISD Quality Procedures Program
certification.
b. Complete Shop Drawings for all the work clearly showing all pieces,
sizes, dimensions, details, connections materials and shop coatings.
1) All Shop Drawings must be checked and signed "approved"
before submittal.
2) Show all cuts, copes, and holes.
3) Indicate all shop and field bolts.
4) Indicate all shop and field welds using AWS symbols.
c. Prepare complete erection drawings showing the location and marks of
all pieces.
1) Copies of up-to-date erection drawings shall accompany the
Shop Drawings.
2) Use match marks on the erection drawings to indicate the sheet
number on which each particular member is detailed.
d. Correct any incorrect or unacceptable material or fabrication due to
incorrect detailing, shop work, or erection, without additional charge.
4. Certifications:
a. Certificates of compliance with standards specified for all major
components and fasteners incorporated into work.
b. Copies of current welding certificates for each welder assigned to
perform welding indicating compliance with testing specified by AWS.
c. Welder qualification data and prequalified procedures.
d. Special Inspections reports.
e. Source Quality Control Documentation, including certificate of
compliance stating that the work performed in the fabrication shop was
done in accordance with the approved construction documents.
1) Certification is required only if the fabricator is fabricator
approved by the Building Official.
5. Test reports:
a. Certified copies of mill tests.
b. Test reports for all structural steel work.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Handle and store steel members above ground on skids or other supports.
1. Keep free of dirt and other foreign material and protect against corrosion.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Pipe: ASTM A53/A53M, Grade B (Type E or S) (Fy=35 ksi).
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B. Steel Plate: ASTM A36/A36M.
C. Bolts, Non-high Strength: ASTM A307, Grade A.
D. Washers, Plain (for Non-high Strength Bolts): ASME B18.22.1, Type B.
E. Welding Electrodes:
1. Shielded metal arc: AWS A5.1/A5.1M or AWS A5.5/A5.5M, E70XX or E801X-
X.
2. Submerged arc: AWS A5.17/A5.17M or AWS A5.23/A5.23M, F7XX-EXXX or
F8XX-EXXX-XX.
3. Gas metal arc: AWS A5.18/A5.18M, E70S-X or E70U-1 or AWS
A5.28/A5.28M, ER80S-XX, E80C-XXX.
4. Flux cored arc: AWS A5.20/A5.20M, E7XT-X (except 2, 3, 10, GS), AWS
A5.29/A5.29M, E7XT-X or E8XTX-X, E8XTX-XM.
F. Anchor Rods and Bolts:
1. See Section 03 15 19.
G. Nonshrink Grout: See Specification Section 03 00 05.
2.2 FABRICATION
A. Comply with requirements of applicable building code and AISC 360 with
modifications and additional requirements specified herein.
1. Identify high-strength steel material in fabricated members in accordance
with ASTM A6/A6M.
B. Minimize the amount of field welding.
1. Shop assemble components into largest size possible commensurate with
transportation and handling limitations.
2. Shop connections: Bolted with high-strength bolts or welded.
C. Provide bearing type connections for all bolted connections, unless otherwise noted.
D. Field connections:
1. Provide bolts for all field connections except where shown otherwise on the
Drawings.
2. Use high-strength bolts unless shown or specified otherwise.
E. Accurately mill column end bearing surfaces to true plane.
F. Cut, drill, or punch holes at right angles to surface of metal.
1. Do not make or enlarge holes by burning.
2. Make holes clean cut, without torn or ragged edges.
3. Remove outside burrs resulting from drilling or reaming operations with tool
making 1/16 IN bevel.
4. Provide holes in members to permit connection of work of other trades or
contractors.
G. Make splices only where indicated or where approved.
H. Flame cut bevels for welds, provided such cutting is done automatically.
1. Leave free of burrs and slag by grinding or planing the cut edges.
I. Tolerances (unless noted otherwise on Drawings):
1. When material received from the mill does not satisfy ASTM A6/A6M
tolerances for camber, profile, flatness or sweep, Contractor is permitted to
perform corrective work by the use of controlled heating, and mechanical
straightening, subject to the limitations of the AISC 360.
2. Fabrication tolerance:
a. Member length:
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1) Both ends finished for contact bearing: 1/32 IN.
2) Framing members: 30 FT or less: 1/16 IN.
b. Member straightness:
1) Compression members: 1/1000 of axial length between points
laterally supported.
2) Non-compression members: ASTM A6/A6M tolerance for wide
flange shapes.
c. Free finished members from twists, bends and open joints.
1) Sharp kinks, bends and deviation from the above tolerances are
cause for rejection of material.
2.3 WELDING
A. Comply with AWS D1.1/D1.1M, and other requirements indicated herein, for all
welding, techniques of welding employed, appearance and quality of welds, and
methods used to correct defective work.
1. Qualify joint welding procedures or test in accordance with AWS qualification
procedures.
B. Test and qualify welders, welding operators and tackers in compliance with AWS
D1.1/D1.1M for position and type of welding to which they will be assigned.
1. Conduct tests in presence of approved testing agency.
2. Certification within previous 12 months will be acceptable, provided samples
of the welder's work are satisfactory.
C. Before Starting Welding:
1. Carefully plumb and align members in compliance with specified
requirements.
2. Comply with AWS D1.1/D1.1M, Section 5 for assembly and surface
preparation.
3. Preheat base metal to temperature stated in AWS D1.1/D1.1M.
a. When no preheat temperature is given in AWS D1.1/D1.1M and base
metal is below 50 DEGF, preheat base metal to at least 70 DEGF.
b. Maintain temperature during welding.
c. Preheat surface of all base metal within distance from point of welding
equal to thickness of thicker part being welded or 3 IN, whichever is
greater, to specified preheat temperature.
d. Maintain this temperature during welding.
4. Mark welds with an identifying mark unique to each welder.
D. Low Hydrogen Electrodes: Dry and store electrodes in compliance with AWS
D1.1/D1.1M.
E. Do not perform welding when ambient temperature is lower than 0 DEGF or where
surfaces are wet or exposed to rain, snow, or high wind, or when welders are
exposed to inclement conditions.
2.4 SHOP COATING
A. Refer to Specification Section 09 91 00 and coordinate shop primer, surface
preparation and coating with field applied primers and coatings where specified.
B. Provide suitable methods of handling and transporting painted steel to avoid
damage to coating.
C. Do not coat following surfaces:
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1. Machined surfaces, surfaces adjacent to field welds, and surfaces fully
embedded in concrete.
2. All other members for which no coating is specified.
D. Clean thoroughly all surfaces not coated before shipping.
1. Remove loose mill scale, rust, dirt, oil, and grease.
2. Protect machined surfaces.
3. Galvanize all structural and miscellaneous steel after fabrication per ASTM
A123/A123M.
2.5 SOURCE QUALITY CONTROL
A. Approved Fabricator or Testing Agency Responsibilities:
1. Inspect shop and field welding in accordance with AWS D1.1/D1.1M, Section
6 including the following non-destructive testing:
a. Visually inspect all welds.
2. Prepare and submit inspection and test reports to Engineer.
2.6 GENERAL
A. Contractor is solely responsible for safety.
1. Construction means and methods and sequencing of work is the prerogative
of the Contractor.
2. Take into consideration that full structural capacity of many structural
members is not realized until structural assembly is complete, e.g., until slabs,
decks, bracing, or rigid connections are installed.
3. Partially complete structural members shall not be loaded without an
investigation by the Contractor.
B. Examine work-in-place on which specified work is in any way dependent to ensure
that conditions are satisfactory for the installation of the work.
1. Report defects in work-in-place which may influence satisfactory completion
of the work.
2. Absence of such notification will be construed as acceptance of work-in-place.
C. Field Measurement:
1. Take field measurements as necessary to verify or supplement dimensions
indicated on the Drawings.
2. Contractor is responsible for the accurate fit of the work.
D. Check the elevations of all finished footings or foundations and the location and
alignment of all anchor bolts before starting erection.
1. Notify Engineer of any errors or deviations found by such checking.
PART 3 - EXECUTION
3.1 ERECTION
A. Framing member location tolerances after erection shall not exceed the framing
tolerances listed in the FIELD QUALITY CONTROL Article in PART 3 of this
Specification Section.
B. Erect plumb and level; introduce temporary bracing required to support erection
loads.
C. Use light drifting necessary to draw holes together.
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1. Drifting to match unfair holes is not allowed.
D. Welding:
1. Conform to AWS D1.1/D1/1M and requirements of this Specification Section.
2. Join two (2) sections of steel of different ASTM designations using welding
techniques in accordance with a qualified AWS D1.1/D1.1M procedure.
E. Clean stored material of all foreign matter accumulated during erection period.
F. Clean bearing and contact surfaces before assembly. Fill sleeves/voids around
anchor bolts with nonshrink grout.
G. Column Assemblies Below Elevated Effluent Trough at Aeration Basin
1. Locate and place steel pipe columns prior to installing plate anchor bolts. Use
base/cap plate anchor holes as a template to drill holes for post-installed
anchors.
2. Set column assemblies to proper line with anchor bolt holes.
3. Clean holes and install post-installed anchors in accordance with Specification
Section 03 15 19.
4. Use leveling bolts to level columns.
5. Pack shim space between column cap plate and soffit of effluent trough with
non-shrink, non-metallic grout.
6. After grout above column cap plate has cured, tighten levelling bolts below
column base plate ½ turn.
7. Pack grout solidly between bottom of base plate and bearing surface.
8. Refer to Specification Section 03 00 05 for nonshrink grout requirements.
H. Cast-in-place Anchor Bolts:
1. See Specification Section 03 15 19.
I. Do not use gas cutting to correct fabrication errors.
1. In case members do not fit or holes do not match, ream out the holes and
insert the next larger size bolt.
a. Drill new holes if the connections require new holes.
b. Make no such corrections without prior approval of the Engineer.
2. Burning of holes is not permitted.
J. Provide beveled washers to give full bearing to bolt head or nut where bolts are to
be used on surfaces having slopes greater than 1 in 20 with a plane normal to bolt
axis.
K. After bolts are tightened, double nut anchor bolts to prevent nuts from backing off.
L. After Erection:
1. Grind smooth all sharp surface irregularities resulting from field cutting or
welding. Cold galvanize all field cuts, field welds and/or damaged galvanized
coatings.
M. Mechanical Anchor Bolts and Adhesive Anchor Bolts:
1. See Specification Section 03 15 19.
3.2 FIELD QUALITY CONTROL
A. Special Inspection and Testing:
1. Owner will employ and pay for services of an independent testing agency to
inspect and test structural steel field work for compliance with Specifications.
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2. Contractor responsible for testing to qualify field welders and as needed for
Contractor's own quality control to ensure compliance with Contract
Documents.
3. Contractor provides sufficient notification and access so inspection and testing
can be accomplished.
4. Contractor pays for retesting of failed tests and for additional testing required
when defects are discovered.
5. Special Inspection to be in accordance with the building code.
6. Special Inspection is required for:
a. Material verification of structural steel.
1) Frequency: Prior to being covered up or substantial completion,
b. Inspect structural steel which has been erected.
1) Member locations.
2) Application of joint details at each connection.
3) Frequency: Prior to members being covered up or substantial
completion.
c. Prepare and submit inspection and test reports to Engineer.
1) Assist Engineer to determine corrective measures necessary for
defective work.
B. Erected Framing Tolerance, unless noted otherwise on the Drawings:
1. Do not exceed cumulative effect of rolling, fabrication and erection tolerance
for overall finished dimensions.
2. Erection tolerances are defined relative to member working points and
working lines as follows:
a. Actual center of member at each end for vertical members.
b. Other points may be used, providing they are based on these
definitions.
c. Working line is straight line connecting member working points.
3. Certification by steel erector:
a. Certify the location of erected structural steel is acceptable for
plumbness, level and aligned within tolerances specified.
b. Provide certification upon completion of any part of work.
3.3 CLEANING AND REPAIR OF SHOP PRIMER PAINT
A. After erection, clean all steel of mud or other foreign materials, and repair any
damage.
END OF SECTION
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SECTION 06 64 00
FRP GRATING, HANDRAILS AND STRUCTURAL FABRICATIONS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section Includes fiberglass reinforced plastic (FRP):
1. Grating and Stair Treads
2. Handrail
3. Ladders and Cages
B. Scope of Work: The Contractor shall furnish all labor, materials, equipment, and incidentals
as required to properly install the entire fiberglass reinforced plastic (FRP) Products
specified herein.
C. Related Sections:
1. Division 5 Section 05501 “Anchor Bolts, Expansion Anchors and Concrete Inserts.”
1.3 REFERENCES
A. ASTM International, Inc. (ASTM):
1. D 635 - Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics
in a Horizontal Position
2. D 3647 - Practice for Classifying Reinforced Plastic Pultruded Shapes According to
Composition
3. D 3917 - Specification for Dimensional Tolerance of Thermosetting Glass-Reinforced
Plastic Pultruded Shapes
4. D 4385 - Practice for Classifying Visual Defects in Thermosetting Reinforced Plastic
Pultruded Products
5. E 84 - Surface Burning Characteristics of Building Materials
6. F 1092 - Specification for Fiberglass (GRP) Pultruded Open-Weather Storm and Guard,
Square Railing Systems
B. Occupational Safety and Health Act (OSHA):
1. 29CFR 19.10 Code of Federal Regulations
C. Underwriters Laboratories, Inc. (UL):
1. 94 - Standard for Safety Tests for Flammability of Plastic Materials for Parts in Devices
and Appliances
1.4 PERFORMANCE REQUIREMENTS
A. Design Requirements:
1. Environmental Conditions: Fiberglass fabrications will be exposed to severe
environmental conditions, including temperatures to 120 degrees F with 100-percent
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humidity and hydrogen sulfide gases. All fiberglass components shall have UV
inhibitors.
2. Structural Performance: FRP products shall withstand the effects of gravity loads and
the following loads and stresses within limits and under conditions indicated:
a. OSHA -29 CFR as it pertains to worker safety and walking surfaces for stairs,
ladders, handrail, and platforms.
b. Design all grating support system components based on the load and deflection
criteria specified herein.
c. Design components to support water lines, electrical conduits, control panels,
light posts and other items shown on the Plans.
d. FRP Grating: Designed for applicable dead load plus a walkway live load of
100 lbs per square foot Uniform Load. Deflection shall not exceed 1/4-inch.
e. FRP Structural Shapes: Designed into structures, supporting all applicable loads.
Deflection shall not exceed L/180.
f. FRP Grating and Stair Treads: Designed to support a uniform load of 100 pounds
per square foot with maximum deflection of L/180, but not over 1/4-inch.
Provide extra stiffness around openings.
g. ADA Compliant Grating: Provide maximum gap between bars of 1/2-inch,
designed for 200 lbs per square foot live load with maximum deflection of
1/4-inch.
h. Fiberglass Handrail Posts and Toe Plates:
1) Designed in accordance with OSHA 1910.23 with a minimum safety factor
of 3 for the load requirements.
2) Top rail shall withstand a load of the greater of 200 pounds or 50 pounds
per foot applied in any direction at the top of the railing.
3) All handrails shall comply with ASTM F1092-87.
i. Ladder Rungs: Provide a non-slip surface.
1.5 SUBMITTALS
A. Product Data: For each type of product indicated.
1. Catalog information and catalog cuts showing materials, design tasks, and showing
load, span, and deflection; include manufacturer's specifications.
2. Resin material data, safety sheet, and chemical resistance charts.
3. Color selection chart or samples.
4. Information regarding each type of grating and handrail connection.
B. Shop Drawings:
1. Include plans, elevations, sections, details, and attachments to other work.
2. Show all FRP materials as required and include all dimensions, connections, fasteners,
tolerances, and assembly and installation details as required.
C. Informational Submittals:
1. Manufactures installation instructions.
2. Handling and storage requirements.
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3. Qualification Data: For qualified manufacturer.
4. Certificate of Compliance: For each type of product proposed from manufacturer.
5. Product Test Reports: Based on evaluation of comprehensive tests performed by an
independent laboratory, dated within two years of submittal of a fire-retardant test
report on type of grating proposed.
6. Field quality-control reports.
7. Warranty: Sample of special warranty.
1.6 QUALITY ASSURANCE
A. Manufacturer Qualifications:
1. All items to be provided under this Section shall be furnished only by manufacturers
having a minimum of 10 years’ experience in the design and manufacture of similar
products and systems.
2. Additionally, if requested, a record of at least 5 previous, separate, similar, successful
installations in the last 5 years shall be provided.
3. Manufacturer shall be certified to the ISO 9001-2000 standard.
B. The Installing Contractor shall assure that all field dimensions are taken accurately and
communicated properly to the FRP Fabricator, that other trades will not affect a proper
installation of the FRP, and that all manufacturer’s instruction and recommendations are
followed.
1.7 PROJECT CONDITIONS
A. Field Measurements: Verify actual locations of walls and other construction contiguous
with FRP fabrications by field measurements before fabrication and indicate measurements
on Shop Drawings.
1. Established Dimensions: Where field measurements cannot be made without
delaying the Work, establish dimensions and proceed with fabricating FRP fabrications
without field measurements. Coordinate wall and other contiguous construction to
ensure that actual dimensions correspond to established dimensions.
2. Provide allowance for trimming and fitting at site.
1.8 COORDINATION
A. Coordinate installation of anchorages for FRP fabrications. Furnish setting drawings,
templates, and directions for installing anchorages, including sleeves, concrete inserts,
anchor bolts, and items with integral anchors, which are to be embedded in concrete or
masonry. Deliver such items to Project site in time for installation.
1.9 DELIVERY, STORAGE, AND HANDLING
A. Deliver, handle and store pumping system components in accordance with manufacturer’s
written instructions and the requirements of Division 1 Section 01600, “Startup, Testing,
Commissioning, and Training.”
B. Delivery of Materials:
1. Ship FRP items factory assemble as practical, with ladders fully shop-fabricated and
assembled.
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2. Package and clearly tag parts and assemblies that, out of necessity, are shipped
unassembled in a manner that will protect the materials from damage and facilitate
identification and final assembly in the field.
C. Storage of Products:
1. All materials shall be carefully handled to prevent them from abrasion, cracking,
chipping, twisting, other deformations, and other types of damage. Store adhesives,
resins, and their catalysts and hardeners in dry indoor storage facilities between 70
degrees F and 85 degrees F.
2. If FRP materials are not to be installed immediately, then store to prevent twisting,
bending, breaking, or damage of any kind. Keep material covered to prevent
unnecessary exposure to UV.
1.10 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or
replace FRP grating, handrails and structural fabrications that fail(s) in materials or
workmanship within specified warranty period.
1. Warranty Period: Two (2) years from date of Substantial Completion.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
1. American Grating, LLC
2. Morrison Molded Fiberglass Company (MMFG).
3. Fibergrate Composite Structures, Inc.
4. International Grating, Inc.
5. Seasafe, Inc.
6. Chemgrate Corporate.
2.2 GENERAL REQUIREMENTS
A. All FRP items furnished under this Section shall be composed of fiberglass reinforcement
and resin in qualities, quantities, properties, arrangements, and dimensions as necessary to
meet the design requirements and dimensions as specified in the Contract Documents.
B. FRP items shall be constructed of strand roving, transverse mat, and a synthetic surface veil,
including ultraviolet light inhibitors.
C. All finished surfaces of FRP items and fabrications shall be smooth, resin-rich, and free of
voids without dry spots, cracks, crazes, or unreinforced areas. All glass fibers shall be well-
covered with resin to protect against their exposure to corrosives, wear, or weathering.
D. Surface-Burning Characteristics:
1. As determined by testing identical products according to ASTM E 84 by a qualified
testing agency. Identify products with appropriate markings of applicable testing
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agency.
a. Flame-Spread Index: 25 or less.
2. Gratings shall also have tested burn time of less than 30 seconds and an extent of
burn rate of less than or equal to 10 millimeters per ASTM D635.
2.3 MATERIALS
A. Description:
1. FRP structural shapes and handrail systems shall be a composite of glass
reinforcements and resin mixture of approximately 45 percent resin-to-glass ratio, or
as required to achieve desired properties, manufactured by the pultrusion process,
unless otherwise noted, and free of visual defects. Dimensional tolerances shall
conform to ASTM D 3917.
2. Fittings shall be made from solid blocks derived from pultruded components. The
grating shall be pultruded fiberglass.
B. Resins: Premium grade, chemically resistant, thermosetting vinyl ester containing a UV
inhibitor and a flame retardant. Provide synthetic surface veil and polyurethane coating
protection system on all components.
C. Fiberglass reinforcements shall be Type E glass, unless noted otherwise herein, in
continuous glass fiber strand roving, continuous glass strand mats, and surface mats, which
will produce a resin-rich surface for maximum chemical resistance. Assembled grating
panels shall have a permanently bonded grit, baked epoxy, and anti-skid surface.
D. Provide smooth surfaces with no exposed glass fibers and free of cracks, rips, and blisters.
Manufacture pultruded sections with a colored resin so that the color is throughout the
section. Use one color for all portions of the system. Coat all cut ends with a compatible
resin or a polyurethane coating in accordance with manufacturer's recommendations.
E. All anchors, fasteners and hardware shall be Type 316 stainless steel. All grated, walkway,
ladder rungs, and stair tread surfaces shall have a non-skid grit top surface using coarse
epoxy grit.
F. Products shall have the following minimum structural properties:
Test Method Longitudinal Transverse
Property
ASTM Direction Direction
Tensile Stress. psi D-638 30,000 7,000
Tensile Modules, psi D-638 2.5 x 106 0.8 x 106
Compressive Stress, psi D-695 30,000 15,000
Compressive Modulus, psi D-695 2.5 x 106 1.0 x 106
Flexural Stress, psi D-790 30,000 10,000
Flexural Modulus, psi D-790 1.8 x 106 0.8 x 106
Modules of Elasticity, psi Full Section 2.8 x 106
2.4 GRATING AND STAIR TREADS
A. General:
1. Grating may be either molded sheets or fabricated of pultruded systems.
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2. Assembled using a locking cross-rod design that makes a permanent connection
between the cross-rod and bearing bar and shall be completely bonded into a one-
piece panel.
B. Pultruded Grating:
1. Pultruded type, I-Bar shaped according to ASTM 3647, Type GCOF, pultruded with
ASTM D 3917 dimensional tolerances and defects not exceeding requirements of
ASTM D 4385, Level II.
2. Grating sized by the manufacturer, with bearing bar spacing not to exceed 1-inch, a
maximum 50 percent open area, and crosstie spacing not to exceed 6 inches, unless
permitted by the ENGINEER.
3. Minimum depth 1-1/2-inch.
C. Molded Grating: Fabricated by interweaving continuous glass filaments in both directions,
perpendicular to each other and impregnating them with a thermosetting resin. Provide
1-1/2-inch square by 1-1/2-inch or 1-inch thick grid pattern. Minimum depth 1-1/2-inch.
D. Requirements: Provide 1-1/2-inch minimum bearing surface, with a minimum bearing of
1-inch after maximum displacements to restraints. Anchors shall be spaced at a maximum
of 18 inches on centers on each support. Grating shall have a maximum glass content of
70 percent.
1. Color: Gray.
2. Grating and Stair Treads shall be made from pultruded bearing bars and cross rods.
3. Stair Treads shall have a square tube nosing.
4. Grating shall have a slip resistant epoxy grit surface.
5. Grating clips shall be Type 316 stainless steel. Minimum of 4 clips per piece.
E. Bolts and Connectors:
1. Corrosion-resistant FRP or Type 316 stainless steel.
2. Size and strength to meet UBC requirements.
2.5 GRATING EMBED FRAMES
A. Requirements:
1. All FRP Grating set in concrete openings shall have an FRP embed angle frame.
2. Embed angle frames to be EBA-10, EBA-15, or EBA-20 as required for the grating
specified above.
3. Embed angles shall have continuous integral anchor.
4. FRP embed angle frames shall be vinyl ester.
2.6 STRUCTURAL COMPONENTS
A. Provide all necessary beam cross-members, connection angles, fasteners, and mounting
brackets, designed and sized by manufacturer. Structural shapes shall be fabricated with
good workmanship, closely fitted joints, and finished true to line and in accurate position to
permit installation and proper joining of parts in the field.
1. Minimum Thickness:
a. Primary structural components (main beams) shall be 3/8-inch.
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b. All other components shall be 1/4-inch.
2. Field verify dimensions and arrangement prior to fabrication.
3. Use Type 316 stainless steel bolts and washers.
4. All joint surfaces to be bonded shall be abraded to remove surface gloss and be free of
burrs or other foreign materials that would prevent proper adhesion.
5. Use high-strength epoxy adhesives designed for FRP use and mechanical fasteners.
6. All pieces to have easily identified part numbers or piece marks.
7. Shop assemble pieces into the largest practical assembly suitable for shipping.
B. Deflection and Safety Factors:
1. Deflection Criteria: Not to exceed L/360.
2. Safety Factors: Minimum ratios of the ultimate stress to the allowable static service
stress:
a. Flexural Members: 2.5.
b. Compression Members: 3.0.
c. Shear: 3.0.
d. Connections: 4.0.
3. Minimum design safety factors for dynamic or impact loads shall be twice the values
for static service loads.
C. Loads:
1. 100 lbs per square foot uniform live load over platform.
2. Static and dynamic loads for equipment shown.
2.7 FRP STAIRS
A. As specified in Part 2:
1. Fabricate from FRP structural shapes as noted.
2. Use OSHA standards for rise and run.
3. Use Stair Treads as specified.
4. Use FRP handrail as specified.
5. Use Type 316 stainless steel bolts throughout.
2.8 HANDRAIL
A. Handrail System: Consist of top and intermediate rails, post, kickplates, and required
anchors and fasteners. Handrail system shall be a standard 2-rail design, unless noted
otherwise.
1. Handrail system shall comply with ASTM F-1092.
2. Handrail posts and rail shall be 2-inch x 2-inch x ¼-inch square tube. All posts and rails
shall use the same tube size. All tubing for handrail to have a minimum 1/4-inch
nominal wall thickness.
3. All post-to-rail connections to be fully-bonded with an epoxy adhesive and shall have
a 1-1/2” square solid internal connection plug for added strength and durability. All
connections to have a smooth transition between post and rail.
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4. Posts to have a maximum spacing of 6 feet o.c.
5. Color: Safety yellow.
2.9 LADDERS AND CAGES
A. Ladders:
1. Ladder Rails: 2-inch x 2-inch x ¼-inch square tube; ladder rungs 1-inch diameter solid
round.
2. Ladder Rungs:
a. Penetrate inside wall of ladder rail tube, countersunk into outside wall of ladder
rail tube, providing support for the ladder rung in 4 places.
b. This connection is to be fully bonded, with epoxy adhesives, and pinned to
prevent rung rotation.
c. Provide slip-resistant quartz epoxy grit surface on ladder rungs.
3. Ladder Stand-off Brackets: FRP and installed on 6 feet centers, maximum.
4. Ladder Base Mount Brackets: FRP construction with bolts of Type 316 stainless steel.
5. Color: Safety yellow.
B. Ladder Cages:
1. Fabricated from FRP Hoops and Straps.
2. FRP Hoops are to be 3-inch x ¼-inch preformed FRP. Hoop spacing shall be a maximum
of 4’-0” on center.
3. FRP Straps are to be 2-inch x ¼-inch FRP and are to be spaced at 9” on center.
4. Hoops and Straps are to be bonded with epoxy adhesives and riveted with Type 316
stainless steel rivets.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install all fiberglass components in accordance with the manufacturer's instructions, shop
drawing, Drawings and Division 1 Section 01200, “Project Administration.” All items shall be
shop-fabricated to the required dimensions and tolerances. Joints to be completed in the
field shall be prepared in the factory with correct bevels, and supplied with kits and
instructions for completing joints. All cut or machined edges shall be ground smooth and
sealed with a compatible bonding resin. Provide and install necessary internal and external
joint reinforcements, connections, and anchors.
B. Components shall be installed accurately to alignments and elevations shown, with bridge
and handrails level, and handrail posts plumb to within 1/4-inch. Anchor the posts securely
as recommended by the fiberglass bridge manufacturer. Install the existing or replacement
water lines, conduits, light posts, control panels, and other items, as shown on the drawings.
C. Erect floor gratings in place on supporting members with full, uniform bearing on supports.
Wedges or shimming devices will not be permitted. Lock grating panels securely in place
with removable hold-down fasteners. Not more than 1/4-inch clearance shall exist between
grating sections or grating frames. Each section shall be readily removable, except as
indicated on Drawings. Adjacent sections shall fit together with transverse members
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forming uninterrupted straight lines.
D. Provide openings and holes as required. Provide openings in gratings indicated for
protrusions as required for installing piping, wiring, and equipment. End cuts shall be
coated with resin per the manufacturer's recommendations. Gratings which fit around
protrusions shall be discontinuous at centerline of opening so each section of grating is
readily removable. Gratings shall be fabricated free from warps, twists, or other defects
which affect appearance and serviceability. No section of grating shall exceed 125 pounds.
E. All fiberglass shall be cleaned of foreign material in accordance with manufacturer's
instructions. Materials containing defects, such as nicks, gouges, blisters, sharp projections,
delamination’s, or exposed fibers shall not be accepted until repaired or replaced as
directed by ENGINEER and OWNER.
END OF SECTION
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PAGE INTENTIONALLY LEFT BLANK
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SECTION 07 92 00
JOINT SEALANTS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Sealing all joints which will permit penetration of dust, air or moisture.
B. Related Specification Sections include but are not necessarily limited to:
1. Division 00 - Procurement and Contracting Requirements.
2. Division 01 - General Requirements.
1.2 QUALITY ASSURANCE
A. Referenced Standards:
1. American Association of State Highway and Transportation Officials
(AASHTO):
a. M 235, Standard Specification for Epoxy Resin Adhesives.
2. American Concrete Institute (ACI):
a. 302.1R, Guide for Concrete Floor and Slab Construction.
3. ASTM International (ASTM):
a. C834, Standard Specification for Latex Sealants.
b. C881, Standard Specification for Epoxy-Resin-Base Bonding Systems
for Concrete.
c. C882, Standard Test Method for Bond Strength of Epoxy-Resin Systems
Used with Concrete by Slant Shear.
d. C920, Standard Specification for Elastomeric Joint Sealants.
e. C1521, Standard Practice for Evaluating Adhesion of Installed
Weatherproofing Sealant Joints.
f. D412, Standard Test Methods for Vulcanized Rubber and
Thermoplastics Elastomers—Tension.
g. D570, Standard Test Method for Water Absorption of Plastics.
h. D624, Standard Test Method for Tear Strength of Conventional
Vulcanized Rubber and Thermoplastic Elastomers.
i. D638, Standard Test Method for Tensile Properties of Plastics.
j. D695, Standard Test Method for Compressive Properties of Rigid
Plastics.
k. D732, Standard Test Method for Shear Strength of Plastics by Punch
Tool.
l. D790, Standard Test Methods for Flexural Properties of Unreinforced
and Reinforced Plastics and Electrical Insulating Materials.
4. NSF International (NSF):
a. 61, Drinking Water System Components -- Health Effects.
5. Underwriters Laboratories, Inc. (UL).
B. Qualifications: Sealant applicator shall have minimum five years experience using
products specified on projects with similar scope.
C. Mock-Ups:
1. Before sealant work is started, a mock-up of each type of joint shall be sealed
where directed by the Engineer.
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a. The approved mock-ups shall show the workmanship, bond, and color
of sealant materials as specified or selected for the work and shall be
the minimum standard of quality on the entire project.
b. Each sample shall cure for a minimum of seven days at which time the
sealant manufacturer's authorized factory representative shall perform
adhesion tests on each sample joint.
1) Perform adhesion tests per ASTM C1521.
2) If mock-up is not acceptable or if adhesion test fails, provide
additional mock-up and adhesion testing as required until
acceptable to Engineer.
1.3 DEFINITIONS
A. Corrosive Areas Include: Aeration Basin.
B. Defect(ive): Failure of watertightness or airtightness.
C. Finish sealant: Sealant material per this specification applied over face of
compressible sealant or expanding foam sealant specified, to provide a finished,
colored sealant joint.
D. Installer or Applicator:
1. Installer or applicator is the person actually installing or applying the product
in the field at the Project site.
2. Installer and applicator are synonymous.
E. "Seal," "sealing" and "sealant": Joint sealant work.
1.4 SUBMITTALS
A. Shop Drawings:
1. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
2. Product technical data including:
a. Acknowledgement that products submitted meet requirements of
standards referenced.
b. Manufacturer's installation instructions.
c. Manufacturer's recommendations for joint cleaner, primer, backer rod,
tooling and bond breaker.
3. Certification from sealant manufacturer stating product being used is
recommended for and is best suited for joint in which it is being applied.
4. Certification of applicator qualification.
B. Test Results:
1. Provide adhesion test results for each sealant sample including adhesion
results compared to adhesion requirements.
2. Manufacturer's authorized factory representative recommended remedial
measures for all failing tests.
C. Samples:
1. Cured sample of each color for Engineer's color selection.
2. Color chart not acceptable.
D. Informational Submittals:
1. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
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0537-038-01 JOINT SEALANTS JANUARY 2023
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver material in manufacturer's original unopened containers with labels intact:
Labels shall indicate contents and expiration date on material.
B. Store all materials off the ground and protect from rain, freezing or excessive heat
until ready for use.
C. Condition specified materials as recommended by the manufacturer.
1.6 PROJECT CONDITIONS
A. Schedule installation of sealant work after completion of penetrating item installation
but prior to covering or concealing of openings.
B. Verify existing conditions and substrates before starting work. Correct unsatisfactory
conditions before proceeding.
C.During installation provide masking and drop cloths to prevent sealant materials
from contaminating any adjacent surfaces.
D. Do not apply material if it is raining or snowing or if such conditions appear to be
imminent. Minimum application temperature 40°F and rising.
1.7 WARRANTY
A. Provide a written warranty from the manufacturer against defects of materials for a
period of one (1) year, beginning with the date of substantial completion of the
project.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following manufacturers are
acceptable:
1. Compressible sealant:
a. Schul International Company, LLC.
b. Emseal by Sika.
c. Norton.
d. Sandell Moisture Protection Systems.
2. Polyether sealants:
a. Master Builders Solutions.
b. Chem Link.
c. Tremco Commercial Sealants & Waterproofing.
3. Polysulfide rubber sealant:
a. Pecora Corporation.
b. Master Builders Solutions.
c. PolySpec by ITW Polymers Sealants.
4. Polyurea joint filler:
a. Dayton Superior Corporation.
b. Euclid Chemical Company.
c. L&M by LATICRETE International, Inc.
d. Master Builders Solutions.
5. Polyurethane sealants:
a. Pecora Corporation.
b. Sika.
c. Master Builders Solutions.
d. Tremco Commercial Sealants & Waterproofing.
6. Silicone sealants:
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0537-038-01 JOINT SEALANTS JANUARY 2023
a. Chem Link.
b. GE Silicones.
c. Dow.
d. Tremco Commercial Sealants & Waterproofing.
7. Backer rod, compressible filler, primer, joint cleaners, bond breaker:
a. As recommended by sealant manufacturer.
8. Expansion Joint Sealing System:
a. Sika.
B. Submit request for substitution in accordance with Specification Section 01 60 00.
2.2 MATERIALS
A. Sealants - General:
1. Provide colors matching materials being sealed.
2. Where compound is not exposed to view in finished work, provide
manufacturer's color which has best performance.
3. Non sagging sealant for vertical and overhead horizontal joints.
4. Sealants for horizontal joints: Self-leveling pedestrian/traffic grade.
5. Joint cleaner, primer, bond breaker: As recommended by sealant
manufacturer.
6. Sealant backer rod and/or compressible filler:
a. Closed cell polyethylene, polyethylene jacketed polyurethane foam, or
other flexible, nonabsorbent, non-bituminous material recommended
by sealant manufacturer to:
1) Control joint depth.
2) Break bond of sealant at bottom of joint.
3) Provide proper shape of sealant bead.
4) Serve as expansion joint filler.
B. Compressible Sealant:
1. For joints exposed to wastewater fumes or vapor:
a. Closed cell ethylene vinyl acetate (EVA) foam with epoxy adhesive.
b. Schul "HydroStop".
2. For all other applications: Foamed polyurethane strip saturated with
polymerized polybutylene waterproofing coated on front face with nonreactive
release agent that will act as bond breaker for applied sealant.
a. Schul "Sealtite B".
3. Adhesive: As recommended by sealant manufacturer.
C. Polyether Sealant:
1. Silyl-terminated polyether polymer.
2. ASTM C920, Type S, Grade NS, Class 50, Use NT, M, A, and O.
a. Master Builders Solutions MasterSeal 150.
b. Chem Link DuraLink.
c. Tremco Dymonic FC.
D. Polysulfide Rubber Sealant:
1. One or two component.
2. Meet ASTM C920.
a. Pecora Synthacalk GC2+.
b. PolySpec THIOKOL 2235.
E. Polyurea Joint Filler:
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0537-038-01 JOINT SEALANTS JANUARY 2023
1. Two component, semi-rigid material for filling formed or saw-cut control
joints in interior concrete slabs.
a. Dayton Superior Corporation "Joint Fill, Joint Seal, Joint Saver II" as
required for condition and recommended by manufacturer.
b. Euclid Chemical Company "EUCO QWIK" joint.
c. L&M "Joint Tite 750".
d. Master Builders Solutions MasterSeal “CR100" control joint filler.
2. Comply with ACI 302.1R performance recommendations regarding control
and construction joints.
3. Color: Gray.
F. Polyurethane Sealant:
1. One or two components.
2. Paintable.
3. Meet ASTM C920 Type S or Type M, Grade NS or P, Class 25, Use NT, T, M, A
and O.
a. Pecora Dynatrol-IXL, Dynatrol II, Urexpan NR-200, NR-201.
b. Sika Chemical Corporation Sikaflex-1a, Sikaflex-2C NS/SL.
c. Master Builders Solutions MasterSeal NP-1, NP-II, SL-1 SL-2.
d. Tremco Dymonic or Dymeric, Vulkem 116,227,45,245.
G. Silicone Sealant:
1. One component.
2. Meet ASTM C920, Type S, Grade NS, Class 25, Use NT, G, A, O.
a. Chem Link DuraSil.
b. GE Silpruf, Silglaze II.
c. GE Sanitary 1700 sealant for sealing around plumbing fixtures.
d. Dow 786 for sealing around plumbing fixtures.
e. Dow 7565, 790, 791, 795.
f. Tremco Spectrem 1, Spectrem 3, Tremsil 600.
3. Mildew resistant for sealing around plumbing fixtures.
H. Expansion Joint Sealing System:
1. Sika Corporation Sikadur Combiflex SG or approved equal.
2. Resin Adhesive:
a. Component A shall be a modified epoxy resin of the epichlorohydrin
bisphenol A type containing suitable viscosity control agents and
pigments. It shall not contain butyl glycidyl ether.
b. Component B shall be primarily a reaction product of a selected amine
blend with an epoxy resin of the epichlorohydrin bisphenol A type
containing suitable viscosity control agents, pigments, and accelerators.
c. The ratio of component A to component B shall be 1:1 by volume.
d. Mixed uncured epoxy resin adhesive properties:
1) Pot life: 30 minutes.
2) Consistency: non-sag (1/2 IN thick).
3) Color: gray.
4) Tack-free time to touch: 2-3 hours (73F).
e. Cured epoxy resin adhesive properties:
1) Tensile properties (ASTM D638) at 14 days:
a) Tensile strength: 3,300 psi.
b) Elongation at break: 0.9%.
2) Compressive properties (ASTM D695) at 28 days:
a) Compressive strength: 16,000 psi.
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0537-038-01 JOINT SEALANTS JANUARY 2023
b) Compressive Modulus of Elasticity: 795,000 psi.
3) Flexural properties (ASTM D790) at 14 days:
a) Flexural strength (Modulus of Rupture): 6,100 psi.
6
b) Tangent Modulus of Elasticity in Bending: 1.67 x 10 psi.
4) Shear strength (ASTM D732) at 7 days: 4,600 psi.
5) Water absorption (ASTM D570), 7 day, (24 hour immersion):
0.07%.
6) Bond strength (ASTM C882) Hardened Concrete to Hardened
Concrete:
a) 2-day (dry cure) bond strength: 2,200 psi.
b) 14-day (moist cure) bond strength: 2,900 psi.
7) The epoxy resin shall conform to ASTM C881 and AASHTO
M235.
3. Sheeting:
a. Sheeting shall be composed of Flexible Polyolefin (FPO) rubber.
b. The sheeting shall be supplied in 20-foot or 82-foot rolls. It shall be
available in 4-inch, 8-inch, and 12-inch widths, at 40 mils thickness.
c. The sheeting shall be supplied with a removable center expansion strip.
d. Sheeting properties:
1) Tensile properties (ASTM D412):
a) Tensile strength: 1,740 psi.
b) Elongation at break: >600%.
2) Tear resistance: (ASTM D624) Die C:
a) Resistance to tear: 69 pounds/inch.
3) Low temperature of performance: Maintained to -40F.
4) Ozone resistance (3-month exposure):
a) Water/ozone (3 ppm) – no effect.
b) Air/ozone (2-300 ppm) - no effect.
PART 3 - EXECUTION
3.1 PREPARATION
A. Before use of any sealant, investigate its compatibility with joint surfaces, fillers, and
other materials in joint system.
B. Use only compatible materials.
C. Where required by manufacturer, prime joint surfaces.
1. Limit application to surfaces to receive sealant.
2. Mask off adjacent surfaces.
D. Provide joint depth for joints receiving polyurea joint filler in accordance with
manufacturer's recommendations.
3.2 INSTALLATION
A. Install products in accordance with manufacturer's instructions and UL requirements.
B. Clean all joints.
C. Make all joints water and airtight.
D. At changes in direction of joints, joint intersections and where sealant joints
interface with other construction, install continuous sealant as necessary to ensure a
weather-tight seal.
E. Make depth of sealing compounds, except expanding foam and polyurea sealant, not
more than one-half width of joint, but in no case less than 1/4 IN nor more than 1/2
IN unless recommended otherwise by the manufacturer.
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0537-038-01 JOINT SEALANTS JANUARY 2023
F. Provide correctly sized backer rod, compressible filler or compressible sealant in all
joints to depth recommended by manufacturer:
1. Take care to not puncture backer rod and compressible filler.
2. Provide joint backer rod as recommended by the manufacturer for polyurea
joint filler.
G. Apply bond breaker where required.
H. Tool sealants using sufficient pressure to fill all voids.
I. Upon completion, leave sealant with smooth, even, neat finish.
J. Where piping, conduit, ductwork, etc., penetrate wall, seal each side of wall
opening.
K. Install compressible sealant to position at indicated depth.
1. Size so that width of material is twice joint width.
2. Take care to avoid contamination of sides of joint.
3. Protect side walls of joint (to depth of finish sealant).
4. Install with adhesive faces in contact with joint sides.
5. Install finish sealant where indicated.
3.3 SEALANT WORK
A. General:
1. Work includes but is not limited to: Sealing all joints which will permit
penetration of dust, air, or moisture.
2. Refer to SCHEDULE for materials to be used.
B. Concrete joints:
1. Isolation joints.
2. Joints between paving or sidewalks and building.
3. Construction, control and expansion joints.
C. Other joints where sealant, expanding foam sealant or compressible sealant is
indicated.
3.4 EXPANSION JOINT SEALING SYSTEM WORK:
A. Surface Preparation:
1. The concrete substrate must be clean, dry, sound and free of surface
contaminants. Remove dust, laitance, grease, oils, curing compounds, form
release agents and foreign particles by mechanical means (i.e. sandblasting,
etc., as approved by Engineer).
B. Mixing and Application:
1. Per manufacturer recommendations.
C. Cleaning:
1. Leave finished work and work area in a neat, clean condition without
evidence of spillovers onto adjacent areas. Clean spillovers with approved
solvent for uncured epoxy resin adhesive or by mechanical means for cured
epoxy resin adhesive.
3.5 FIELD QUALITY CONTROL
A. Adhesion Testing:
1. Perform adhesion tests in accordance with ASTM C1521 per the following
criteria:
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0537-038-01 JOINT SEALANTS JANUARY 2023
a. Water bearing structures: One test per every 1000 LF of joint sealed.
b. All other type of joints except butt glazing joints: One test per every
3000 LF of joint sealed.
c. Manufacturer's authorized factory representative shall recommend, in
writing, remedial measures for all failing tests.
3.6 SCHEDULE
A. Furnish sealant as indicated for the following areas:
1. Exterior areas:
a. Above grade: Polyether.
b. Below grade: Polyurethane.
2. Immersion:
a. Prolonged contact with or immersion in:
1) Non potable water, wastewater or sewage: Polysulfide.
3. Compressible sealant: Where indicated.
END OF SECTION
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SECTION 09 91 00
PAINTING AND PROTECTIVE COATINGS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section includes the surface preparation and application of high-performance coating
systems on the following substrates:
Exterior substrates:
Concrete, vertical,and horizontal surfaces.
Steel.
Galvanized metal.
Aluminum (not anodized or otherwise coated).
Interior Surfaces:
Concrete.
Steel.
Galvanized metal.
Aluminum (not anodized or otherwise coated).
Related Sections:
Applicable equipment Sections for manufacturer’s special coatings of equipment.
1.3REFERENCES AND DEFINITIONS
References:
ASTM International (ASTM)
D16 -Definitions of Terms Relating to Paint, Varnish, Lacquer, and Related
Products.
D2016 -Test Method for Moisture Content of Wood.
The Society for Protective Coatings (SSPC)
SSPC Painting Manual, “Good Painting Practice”
SSPC Painting Manual, “Systems and Specifications”
SSPC-SP1 Solvent Cleaning
SSPC-SP3 Power Tool Cleaning
SSPC-SP5 White Metal Blasting
SSPC-SP6 Commercial Blast Cleaning
SSPC-SP7 Brush-Off Blast Cleaning
SSPC-SP10 Near-White Blast Cleaning
SSPC-SP12 Surface Preparation and Cleaning of Metals by Waterjetting Prior to
Recoating
SSPC-SP13 Surface Preparation of Concrete
SSPC-SP14 Industrial Blast Cleaning
SSPC-VIS 1 89 Visual Standard for Abrasive Blast Cleaned Steel
NACE International (National Association of Corrosion Engineers International)
RP0287-95 “Field Measurements of Surface Profile of Abrasive Blast Cleaned
Steel Surfaces Using Replica Tape”
RP0188-99 “Discontinuity (Holiday) Testing of Protective Coatings”
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TM-01-70 “Visual Comparator for Surfaces of New Steel Airblast Cleaned with
Sand Abrasive”
TM-01-70 “Visual Comparator for Surfaces of New Steel Airblast Cleaned with
Slag Abrasive”
RP0178-95 “Fabrication Details, SurfaceFinish Requirements, and Proper
Design Considerations for Tanks and Vessels to be Lined for Immersion
Service”
RPO 892-92 “Linings Over Concrete for Immersion Service”
RPO 591-96 “ Coatings for Concrete Surfaces in Non-Immersion”
6G186 “Surface Preparation of Contaminated Steel Surfaces”
6G191 “Surface Preparation of Contaminated Concrete.”
RPO 178 “Weld preparation Visual Comparator.”
National Science Foundations (NSF)
Definitions:
Conform to ASTM D16 for interpretation of terms used in this Section.
Exposed Surfaces: Used to define painting locations and requirements it shall include
all visible interior or exterior surfaces, top of walls, ceilings, and inside surfaces to
1'-0" below grade or the weir level or to floor level, whichever applies.
1.4SUBMITTALS
Product Data: Submit product data, certificates, and application instructions for each type
of product indicated.
Samples for Initial Selection: For each type of topcoat product indicated.
Samples for Verification: For each type of paint system and in each color and gloss of
topcoat indicated.
Submit Samples on rigid backing, 8 inches square.
Step coats on Samples to show each coat required for system.
Label each coat of each Sample.
Label each Sample for location and application area.
Product List: For each product indicated, include the following:
Show where each coating is to be used on the Project, with cross reference to this
Section paragraphs and Painting Schedule.
Product date and information submitted shall demonstrate compliance with this
Section.
Provide the surface preparation required or recommended by coating manufacturer
for each type of coating application if different from that specified in this Section.
Provide ENGINEER with certification from coating supplier that sufficient paint has been
purchased to provide required quantity of coatings for Project.
Certificate shall list the quantities and types of paint purchased.
Provide ENGINEER with certification from the blast cleaning supplier that sufficient materials
have been purchased to provide for the surface preparation specified for Project.
Certificate shall list the quantities and gradation purchased.
Manufacturer’s Instructions:
Provide manufacturer’s instructions for the application of the coating system for the
purposeintended by these specifications. The instructions shall provide the
limitations, precautions, and requirements that may adversely affect the coating
system; that may cause unsatisfactorily results after the application; or that may
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prevent the coating system not to serve the purpose for which it was intended, which
is to provide coverage and protection from corrosion, shall be clearly stated.
The instructions shall include, but not limited to:
Surface preparation.
Methods of Application.
Number of coats.
Thickness of each coat.
Total Thickness.
Drying time of each coat, including primer.
Drying time of final oat before placement in service.
Time allowed between coats.
Primers required to be used.
Primers not permitted.
Use of a primer.
Compatible topcoats.
Thinner and use f thinner.
Weather limitations during and after application (temperature, humidity, wind
velocity).
Protection from sun.
Physical properties of paint, including percent solids content by volume,
ingredient analysis, and weight perunit surface per dry mil thickness.
Cathodic disbonding limitations, if any.
Equipment settings (air cap, fluid tip, equipment pressure settings, etc.)
Field quality-control reports: Provide temperature and humidity readings, testing for coating
dry mil thickness and bonding, surface preparation, and related coating testing.
Pre-installation Conference: Provide minutes of the pre-installation conference.
1.5QUALITY ASSURANCE
Product Manufacturer: Company specializing in manufacturing quality coating products with
10 years’ experience.
Applicator: Company specializing in industrial painting and finishing with five (5) years
documented experience, approved by product manufacturer.
CONTRACTOR shall apply coatings systems from only one manufacturer for each type of
application.
CONTRACTOR shall coordinate materials to be painted, shop primers, field primers, and
finish coating systems to ensure compatibility for all materials and coatings in this project.
All coatings in contact with potable water and water being treated for use as potable water
shall conform to ANSI/NSF Standard61 and shall be certified by an organization accredited
by ANSI. All process, service water, potable, and chemical piping, fittings, tanks, valves,
equipment, and structures in contact with the water being treated are included in this
requirement.
Coating system manufacturer shall review actual job conditions prior to purchase of any
materials. Manufacturer shall submit to ENGINEER a statement listing any exceptions to the
specifications regarding preparation requirements or coating applicability.
1.6REGULATORY REQUIREMENTS
Conform to applicable code for flame/fuel/smoke rating requirements for finishes.
Preinstallation Conference: Conduct conference at Project site.
1.7DELIVERY, STORAGE, AND HANDLING
Deliver, store, and protect products in accordance with manufacturer's instructions.
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Deliver products to site in the original, sealed, labeled, and unopened containers; inspect to
verify acceptance. Damaged containers will not be accepted.
Container labeling to include manufacturer's name, type of paint, brand name, brand code,
coverage, surface preparation, drying time, cleanup, color designation, and instructions for
mixing and reducing.
Store paint materials in well ventilated areas with ambient temperatures continuously
maintained at not less than 45°F (7°C) and not more than 90°F (32°C).
Take precautionary measures to prevent fire hazards and spontaneous combustion. Remove
oily rags, waste, or other fire hazards from facilities each night. Place cloths and cotton
waste, which might constitute a fire hazard, in metal containers or destroy at the end of
each workday.
1.8PROJECT CONDITIONS
Provide continuous ventilation and heating facilities to maintain surface and ambient
temperatures above 45°F (7°C) for 24 hours before, during, and 48 hours after application
of finishes, unless required otherwise by manufacturer's instructions.
Apply coatings only when temperature of surfaces to be coated and surrounding air
temperatures are between 50 and 95°F (10 and 35°C).
Do not apply coatings in;
snow, rain, mist or fog;
or when relative humidity meets or exceeds 85 percent;
or at temperatures less 5 º F (3 º C) above the dew point; r
or when it is predicted the air temperature will drop below 45 º F (7 º C) or less than 5 º F
(3 º C) above the dew point is forecast within 8 hours after application of coating
unless it is enclosed and heated;
or to damp or wet surfaces.
Minimum Application Temperatures for Latex Paints: 45°F (7°C) for interiors; 50°F (10°C) for
exterior; unless required otherwise by manufacturer's instructions.
Minimum Application Temperature for Varnish and Finishes: 65°F (18°C) for interior or
exterior, unless required otherwise by manufacturer's instructions.
Comply with all manufacturer’s instructions for coating application and environmental
conditions, which may be more stringent than the minimum requirements listed in this
specification.
Provide lighting level of 80-foot candles measured mid-height at substrate surface.
CONTRACTOR shall be fully responsible for personnel safety during painting operations.
Display caution signs in necessary areas advising of spray painting and warning
against open flames.
Provide barriers or shelters on windy days to protect equipment and facilities.
1.9EXTRA MATERIALS
Furnish extra materials that match products installed and that are packaged with protective
covering for storage and identified with labels describing contents.
Furnish an additional 5 percent, but not less than 1 gallon of each material and color
applied.
The material shall be delivered in unopened labeled containers as delivered from the
manufacturer. If the manufacturer does not deliver in gallon containers, and in the
case of special colors, the new gallon containers, properly closed with typed labels
indicating brand, type, color, location used, etc.
Where multiple component materials are used, provide an unopened kit of the
necessary materials in the manufacturer’s smallest standard packaging size. Provide
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three (3) copies of the manufacturer’s instructions describing the materials and
directions for their use.
Provide a typed inventory list of the extra materials furnished at time of delivery.
1.10SPECIAL WARRANTY
Warranty inspection of the coating systems shall be conducted during the eleventh month
following completion and acceptance of all coating system work. The personnel or their
representatives present at the pre-installation conference are requested to attend. All
defective coating systems shall be repaired in accordance with this Section and to the
satisfaction of the ENGINEER and OWNER.
PRODUCTS
2.1PAINT, GENERAL
Material Compatibility:
Provide materials for use within each paint system that are compatible with one
another and substrates indicated, under conditions of service and application as
demonstrated by manufacturer, based on testing and field experience.
For each coat in a paint system, provide products recommended in writing by
manufacturers of topcoat for use in paint system and on substrate indicated.
Chemical Components of Field-Applied Interior Paints and Coatings: Provide topcoat paints
and anti-corrosive and anti-rust paints applied to ferrous metals that comply with the
following chemical restrictions; these requirements do not apply to paints and coatings that
are applied in a fabrication or finishing shop:
Aromatic Compounds: Paints and coatings shall not contain more than 1.0 percent by
weight of total aromatic compounds (hydrocarbon compounds containing one or more
benzene rings).
Restricted Components: Paints and coatings shall not contain any of the following:
Acrolein.
Acrylonitrile.
Antimony.
Benzene.
Butyl benzyl phthalate.
Cadmium.
Di (2-ethylhexyl) phthalate.
Di-n-butyl phthalate.
Di-n-octyl phthalate.
1,2-dichlorobenzene.
Diethyl phthalate.
Dimethyl phthalate.
Ethylbenzene.
Formaldehyde.
Hexavalent chromium.
Isophorone.
Lead.
Mercury.
Methyl ethyl ketone.
Methyl isobutyl ketone.
Methylene chloride.
Naphthalene.
Toluene (methylbenzene).
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1,1,1-trichloroethane.
Vinyl chloride.
2.2COLOR SCHEDULE
Color Selection:
Colors: As selected by OWNER from manufacturer's full range of colors.
Colors selected may or may not be the manufacturer’s standard color.
Submit color charts to OWNER at least 60-days prior to coating application to allow
time for color selection.
Different colors will be selected for concrete structures; building columns, framing,
walls, window and door frames, and other areas; various items of equipment; piping
and conduit; safety colors will be used for fire equipment locations, protective covers
for rotating or moving equipment, walkways, and other related items; architectural
treatment, both interior and exterior of buildings; and for all other items of Work.
Colors for equipment shall be selected by OWNER during submittal process.
Colors selection for piping systems and identification of piping systems shall be in
accordance with Section 10 90 00 “Identification, Stenciling, and Tagging”. Refer to Piping
and Sign Color Code included in this Section for colors for lettering, piping, and background.
2.3MANUFACTURERS
Acceptable Manufacturers: Provide a coating system from one of the manufacturers listed,
if not listed under each Painting System Application:
Carboline Protective Coatings and Linings, St. Louis, MO.
PPG Protective and Marine Coatings (formerlyAmeron Coatings).
Tnemec Company, Inc., Kansas City, MO.
2.4MATERIALS
Coatings: Ready mixed, except field catalyzed coatings. Process pigments to a soft paste
consistency, capable of being readily and uniformly dispersed to a homogeneous coating.
CONTRACTOR shall have complete responsibility for ensuring that each coating applied is
compatible with its substitute and/or its intended finish coat, and that the completed coating
system is suitable for its intended service.
Accessory Materials: Thinning of paint and all accessory type materials used shall be strictly
in accordance with the manufacturer's recommendations covering material types, solvents,
mix ratios, and methods.
EXECUTION
3.1EXAMINATION
Examine substrates and conditions, with Applicator present, for compliance with
requirements for maximum moisture content and other conditions affecting performance of
work.
Maximum Moisture Content of Substrates: When measured with an electronic moisture
meter as follows:
Concrete: 12 percent.
Masonry (Clay and CMU): 12 percent.
Wood: 15 percent.
Gypsum Board: 12 percent.
Plaster: 12 percent.
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Verify suitability of substrates, including surface conditions and compatibility with existing
finishes and primers.
Begin coating application only after unsatisfactory conditions have been corrected and
surfaces are dry.
Beginning coating application constitutes Contractor's acceptance of substrates and
conditions.
3.2PREPARATION
Surface of substrates to be coated shall be prepared in accordance with the SSPC
specification as listed in Part 3.6 and as described in the paragraphs below.
Comply with manufacturer's written instructions and recommendations in "MPI Architectural
Painting Specification Manual" applicable to substrates indicated.
Remove plates, machined surfaces, and similar items already in place that are not to be
painted. If removal is impractical or impossible because of size or weight of item, provide
surface-applied protection before surface preparation and painting.
After completing painting operations, use workers skilled in the trades involved to
reinstall items that were removed. Remove surface-applied protection if any.
Do not paint over labels of independent testing agencies or equipment name,
identification, performance rating, or nomenclature plates.
Clean substrates of substances that could impair bond of paints, including dirt, oil, grease,
and incompatible paints and encapsulants.
Remove unknown primers or coatings systems and incompatible primers of shop
painted work and reprime substrate with compatible primers as required to produce
paint systems indicated.
When removal is not feasible and with approval of ENGINEER, CONTRACTOR
may apply a barrier coat in accordance with coating manufacturer’s instructions
prior to application of the designated coating system.
When sandblasting, use a source of compressed air, which is free of detrimental
water and oil and capable of delivering the required volume and pressure.
Subject to review by ENGINEER, any substrate in which SSPC-SP6 or SSPC-SP10
sandblasting cannot be accomplished shall be cleaned in accordance with SSPC-SP3
removing loose mill scale, rust, paint, and other foreign matter.
Concrete Substrates: Remove release agents, curing compounds, efflorescence, and chalk.
Do not paint surfaces if moisture content or alkalinity of surfaces to be painted exceeds that
permitted in manufacturer's written instructions.
Allow new concrete to cure for 28-days.
Clay Masonry Substrates: Remove efflorescence and chalk. Do not paint surfaces if
moisture content of surfaces or alkalinity of mortar joints to be painted exceeds that
permitted in manufacturer's written instructions.
Concrete Masonry Substrates: Remove efflorescence and chalk. Do not paint surfaces if
moisture content or alkalinity of surfaces to be painted exceeds that permitted in
manufacturer's written instructions.
Steel Substrates: Remove rust and loose mill scale, if work has not been shop primed with
coating system compatible primer. Clean using methods recommended in writing by paint
manufacturer.
Galvanized-Metal Substrates: Remove grease and oil residue from galvanized sheet metal
fabricated from coil stock by mechanical methods to produce clean, lightly etched surfaces
that promoteadhesion of subsequently applied paints.
Aluminum Substrates: Remove surface oxidation.
Wood Substrates:
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Scrape and clean knots, and apply coat of knot sealer before applying primer.
Sand surfaces that will be exposed to view, and dust off.
Prime edges, ends, faces, undersides, and backsides of wood.
After priming, fill holes and imperfections in the finish surfaces with putty or plastic
wood filler. Sand smooth when dried.
Gypsum Board Substrates: Do not begin paint application until finishing compoundis dry
and sanded smooth.
Plaster Substrates: Do not begin paint application until plaster is fully cured and dry.
Spray-Textured Ceiling Substrates: Do not begin paint application until surfaces are dry.
Cotton or Canvas Insulation Covering Substrates: Remove dust, dirt, and other foreign
material that might impair bond of paints to substrates.
3.3PROTECTION
Protect elements surrounding the work of this Section from damage or disfiguration.
Repair damage to other surfaces caused by work of this Section.
Furnish drop cloths, shields, and protective methods to prevent spray or droppings from
disfiguring other surfaces.
Remove empty paint containers from site and dispose of all excess materials and empty
containers in full accordance with all applicable state, federal, and local laws.
3.4APPLICATION
Minimum Dry Film Thickness (MDF). Where applicable, the Coating Schedule includes the
minimum dry film thickness required for the various coating systems specified. The film
thickness is measured in mils.
Apply products in accordance with manufacturer's instructions in regard to drying time
between coats, technique of application, ventilation, paint thinning, and safety precautions.
Use applicators and techniques suited for paint and substrate indicated.
Paint surfacesbehind movable equipment and furniture same as similar exposed
surfaces. Before final installation, paint surfaces behind permanently fixed equipment
or furniture with prime coat only.
Paint front and backsides of access panels, removable or hinged covers, and similar
hinged items to match exposed surfaces.
Allow applied coat to dry for the time period specified by the coating manufacturer before
next coat is applied. Do not apply finishes to surfaces that are not dry to touch.
Apply each coat to uniform finish; free from runs, drips, ridges, waves, laps, brush marks
and variations in color, texture and finish.
Where multiple coats are specified; apply each coat in a different color, which compliments
the following coat and is different than the proceeding coat. Each coat must be free of
shadows and uniform in appearance.
Sand lightly between coats to achieve required finish
Double-lap all welds. Apply prime coat by brush to all weld areas; then apply prime coat to
entire surface, including weld areas.
Where clear finishes are required, tint fillers to match wood.Work fillers into the grain
before set.Wipe excess from surface.
Prime back surfaces of interior and exterior woodwork with primer paint.
Prime back surfaces of interior woodwork scheduled to receive stain or varnish finish with
gloss varnish reduced 25 percent with mineral spirits.
Paint all items throughout the project except for surfaces listed below unless shown
otherwise in the plans or specifications:
Concrete walkways, pavement, sidewalks, and stair treads.
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Interior fiberglass items unless specified otherwise. Exterior fiberglass shall be
painted.
Metal surfaces of anodized aluminum, stainless steel, or chromium plate.
Operating parts, unless otherwise specified.
Existing structures or equipment, unless otherwise specified.
Equipment, valve, and other items nameplates or serial numbers.
Valve operator stems.
Repair any damage or overspray to paint on existing structures caused by construction
work. Match existing colors with touch-up paint.
New concrete and rubbed finish and mortar joints shall age a minimum of 30days before
application of coatings.
Concrete surfaces to be painted shall be coated prior to installation of equipment, piping,
conduit and supports and touched up following installation of these items. Components,
which cannot be adequately painted due to space limitations following installation, shall be
coated prior to installation and touched up after installation as well.
Where inspection shows that the specified thickness is not developed, apply additional coats
in accordance with manufacturer’s instructions and cure schedule requirements to produce
the required dry film thickness.
3.5FINISHING MECHANICAL AND ELECTRICAL EQUIPMENT
Refer to Section 10 90 00 “Identification, Stenciling, and Tagging”, and Section260553
“Identification for Electrical Systems”, for requirements for color-coding and identification
banding of ductwork, piping, conduit, and identification systems.
Paint shop primed equipment.Touchup paint equipment furnished with factory coatings
with manufacturer’s correct color.
Remove unfinished louvers, grilles, covers, and access panels on mechanical and electrical
components and paint separately.
Prime and paint insulated and exposed pipes, conduit, boxes, insulated and exposed ducts,
hangers, brackets, collars and supports. For insulated pipe, provide shop and field primer
coats on pipe and surface preparation and final coat on insulation jacket.
Replace identification markings on mechanical or electrical equipment when painted
accidentally.
Paint interior surfaces of air ducts, and convector and baseboard heating cabinets that are
visible through grilles and louvers with one coat of flat black paint, to limit of sight
line.Paint dampers exposed behind louvers, grilles, and convector and baseboard cabinets
to match face panels.
Paint exposed conduit and electrical equipment occurring in finished areas.
Paint both sides and edges of plywood backboards for electrical and telephone equipment
beforeinstalling equipment.
Color code equipment, piping, conduit, and exposed ductwork in accordance with
requirements indicated. Color band and identify with flow arrows and names.
Replace electrical plates, hardware, light fixture trim, and fittings removed prior to finishing.
Coating systems applied at the factory shall be protected against damaged during transit,
delivery, storage, and erection. Damaged areas shall be refinished as the original so that
end of the Project the finish will be in perfect shape.
The following items shall receive factory applied coatings:
Electrical panels, motor control centers, transformers, and related items.
Light fixtures.
Pressure gauges.
Instrumentation.
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3.6SURFACE PREPARATION AND COATING SCHEDULE
All surfaces in contact with potable water:
Surface Preparation:
Interior Ferrous Metals, submerged or intermittently submerged:
SSPC-SP10, Near White Blast.
Interior Ferrous Metals dry:
SSPC-SP6, Commercial Blast.
Concrete:
Brush Blast.
Products and Manufacturer (only use products approved by NSF 61):
Tnemec:
Primer: Series 94-H2O Hydro-Zinc -1 coat, 2.5-3.5MDF.
Stripe Coat: Series 20-15BL Pota-Pox applied by brush and scrubbed into
all weld seams.
Finish: Series 141 Epoxoline -1 coat, 12.0-15.0MDF.
PPG:
Primer: Amerlock 2 -1 coat 5.0 MDF.
Finish: Amerlock 2 -1 coat 5.0 MDF.
Or approved equivalent by named manufacturers.
All Aluminum in Contact with Dissimilar Materials:
Surface Preparation: Remove all foreign matter.
Product and Manufacturer: Provide one of the following:
Tnemec:
Series 66 Hi-Build Epoxoline -2 coats, 4.0 MDF per coat
Carboline:
Carboline 893 -2 coats, 4.0 MDF per coat.
PPG:
Amercoat 385 Polyamide Epoxy -2 coats, 4.0 MDF per coat.
Exposed Uninsulated PVC Piping and FRP Components, Interior and Exterior where painting
is required.
Surface Preparation: As recommended by coating manufacturer.
Product and Manufacturer: Provide one of the following:
Tnemec:
Finish: Series 66 Hi-Build Epoxoline -1 coat, 4.0 MDF.
Carboline:
Finish: Carboline 890 -1 coat, 4.0 MDF.
PPG:
Finish: Amercoat 385 Polyamide Epoxy -1 coat, 4.0 MDF.
A second finish coating of epoxy urethane, 3.0 MDF, shall be applied on all exterior
PVC and FRP components (TNEMEC Series 1074 or equal by other named suppliers).
All outdoor fiberglass items including FRP protective tank shell on steel tanks, and structural
components shall be coated as follows:
Surface Preparation:
Brush off cleaning, SSPC-SP7.
Solvent cleaning, SSPC-SP1.
Products and Manufacturers:
Tnemec:
Primer: Series 66-Highbuild Epoxoline, 3.0-4.0 MDF. Broom surface after
coating has cured.
Intermediate Coat: Series-Highbuild Epoxoline, 3.0-4.0 MDF.
Finish: Series 290 CRU, 3.0-5.0 MDF.
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PPG:
Primer: Amerlock 400 3.0-4.0 MDF.
Finish: Pitthane Ultra 2.0-3.0 MDF.
Caroline equivalentcoatingsystem.
The intent of this coating specification is to obtain a polyurethane top coat for UV
protection and cosmetic purposes. Primer and intermediate coats, as well as initial
surface preparation shall be as recommended by the coating manufacturer for proper
adhesion and serviceability on the fiberglass items to be painted.
Exposed, Uninsulated Metal Pipe in Marine Environment:
No coating shall be applied to stainless steel piping.
Surface Preparation:SSPC-SP6 Commercial Blast Cleaning. Anchor profile shall be
angular with a 1.5 to 2.0 mil profile as per ASTM D 4417, Method C or NACE Standard
RP0287.
Products and Manufacturers:
Tnemec:
First Coat: Tnemec Series 90G-1K97 Tneme-Zinc, 2.5 –3.5 MDF.
Stripe Coat: Tnemec Series 66 Hi-Build Epoxoline. Brush applied and
scrubbed into all weld seams, edges, corners, bolts, rivets, pits, etc.
Second Coat: Tnemec Series 66 Hi-Build Epoxoline, 4.0 –6.0 MDF.
Third Coat: Tnemec Series 290 CRU, 2.0 –3.0 MDF.
Carboline:
Primer: Carbozinc 849, 2.0 –3.0 MDF.
Intermediate: Epoxy Carboguard 635, 4.0 –6.0 MDF.
Finish: Carbothane 134HG, 2.0 –3.0 MDF.
PPG:
Primer: Amercoat 385,5.0-6.0 MDF.
Intermediate: Amercoat,385 5.0-6.0 MDF.
Finish: Pitthane Ultra,2.0-3.0 MDF.
Exposed Ferrous Surfaces in Marine Environment:
Surface Preparation:
SSPC-SP10 Near-White Blast Cleaning.
Products and Manufacturers:
Tnemec:
First Coat: Tnemec Series 90G-1K97 Tneme-Zinc, 2.5 –3.5 MDF.
Stripe Coat: Tnemec Series 66 Hi-Build Epoxoline. Brush applied and
scrubbed into all weld seams, edges, corners, bolts, rivets, pits, etc.
Second Coat: Tnemec Series 66 Hi-Build Epoxoline, 4.0 –6.0 MDF.
Third Coat: Tnemec Series 290 CRU, 2.0 –3.0 MDF.
Carboline:
Primer: Carbozinc 849, 2.0 –3.0 MDF.
Intermediate: Epoxy Carboguard 635, 4.0 –6.0 MDF.
Finish: Carbothane 134HG, 2.0 –3.0 MDF.
PPG:
Primer: Amercoat 385 5.0-6.0 MDF.
Intermediate: Amercoat 385 5.0-6.0 MDF.
Finish: Pitthane Ultra 2.0-3.0 MDF.
Submerged or Intermittently Submerged Metal Pipe in Marine Environment:
No coating shall be applied to stainless steel piping.
Surface Preparation:
SSPC-SP10 Near-White Blast Cleaning.
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Products and Manufacturers:
Tnemec:
First Coat: Tnemec N69 Hi-Build Epoxoline II, 6.0 –10.0 MDF.
Stripe Coat: Tnemec Series N69 Hi-Build Epoxoline II. Brush applied and
scrubbed into all weld seams, edges, corners, bolts, rivets, pits, etc.
Second Coat: Tnemec N69 Hi-Build Epoxoline II, 6.0 –10.0 MDF.
Third Coat: Tnemec Series 290 CRU, 2.0 –3.0 MDF
Carboline:
Reactamine 760 Series, 25.0 –30.0 MDF.
PPG:
Sigmashield 880 12.0-15.0 MDF.
3.7FIELD QUALITY CONTROL
CONTRACTOR shall be responsible for the following testing during coating operations:
Prior to start and during the coating application each day, temperature and humidity
readings will be obtained. If the values obtained are not within the recommended
temperature and humidity range described herein or as required by the coating
manufacture, the coating application will not be allowed.
Periodically check the wet film thickness during coating applications.
Prepared records of the above tests and readings.
Testing Agency: OWNER will engage a qualified testing agency to perform tests and
inspections.
Minimum Dry Film Thickness (MDF) readings will be obtained after each coat of paint
has been applied, and after final coat has been applied. A test will be made for every
25 square feet of surface and at locations designated by the ENGINEER. A minimum
of three readings of the area around the location will be obtained. If the average of
these readings indicates the MDF for the final coat is below the specified minimum,
CONTRACTOR shall apply another coat in accordance with the manufacturer’s
instructions.
The interiors of liquid containing structures and tanks will be tested for holidays after
final coat application. Areas found to be defected shall have an additional coat
applied.
The coating system will be considered defective if it does not pass tests and inspections.
When this occurs the ENGINEER will specify corrective measures. The coating system will be
retested, with the additional expense occurred charged to the CONTRACTOR. Refer to 01 40
00 “Quality requirements” for addition information regarding retesting and reinspection and
01 70 00 “Execution Requirements” for correction of work.
Testing of Paint Materials: Owner reserves the right to invoke the following procedure at
any time and as often as Owner deems necessary during the period when paints are being
applied:
Owner will engage the services of a qualified testing agency to sample paint materials
being used. Samples of material delivered to Project site will be taken, identified,
sealed, and certified in presence of Contractor.
Testing agency will perform tests for compliance of paint materials with product
requirements.
Owner may direct Contractor to stop applying paints if test results show materials
being used do not comply with product requirements. Contractor shall remove
noncomplying paint materials from Project site, pay for testing, and repaint surfaces
painted with rejected materials. Contractor will be required to remove rejected
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materials from previously painted surfaces if, on repainting with complying materials,
the two paints are incompatible.
Prepare test and inspection reports.
3.8CLEANING AND PROTECTION
At end of each workday, remove rubbish, empty cans, rags, and other discarded materials
from Project site.
After completing paint application, clean spattered surfaces. Remove spattered paintsby
washing, scraping, or other methods. Do not scratch or damage adjacent finished surfaces.
Protect work of other trades against damage from paint application. Correct damage to
work of other trades by cleaning, repairing, replacing, and refinishing, as approved by
Architect, and leave in an undamaged condition.
At completion of construction activities of other trades, touch up and restore damaged or
defaced painted surfaces.
During progress of Work maintain premises free of unnecessary accumulation of tools,
equipment, surplus materials, and debris.
Collect cotton waste, cloths, and material which may constitute a fire hazard, place in closed
metal containers and remove daily from site.
Upon completion of the work remove all staging and scaffolding. Dispose of all sand,
containers, ad rubbish in a suitable manner. Remove overspray, paint spots, oil or stains on
adjacent surfaces. Leave the entire Project clean and acceptable.
END OF SECTION
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SECTION 09 97 13.26
COATING OF MICROPILE CASINGS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Coating of micropile casings.
B. Related Specification Sections include but are not necessarily limited to:
1. Division 00 - Procurement and Contracting Requirements.
2. Division 01 - General Requirements.
3. 31 62 18 - Micropiles
1.2 QUALITY ASSURANCE
A. Referenced Standards:
1. ASTM International (ASTM):
a. D7091, Standard Practice for Nondestructive Measurement of Dry Film
Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and
Nonmagnetic, Nondestructive Coatings Applied to Non-Ferrous Metals.
b. E376, Measuring Coating Thickness by Magnetic-Field or Eddy-Current
(Electromagnetic) Test Methods.
2. National Association of Corrosion Engineers (NACE):
a. RPO 188-88, Standard Recommended Practice for Discontinuity
(Holiday) Testing of Protective Coatings.
3. The Society for Protective Coatings (SSPC):
a. PS 11.01, Black (or Dark Red) Coal Tar Epoxy-Polyamide Painting
System.
b. PS 13.01, Epoxy-Polyamide Painting System.
c. PA 2, Measurement of Dry Coating Thickness With Magnetic Gages.
d. Paint 16, Paint Specification No. 16 Coal Tar Epoxy-Polyamide Black (or
Dark Red) Paint.
e. Paint 20, Paint Specification No. 20 Zinc-Rich Coating Type I Inorganic
and Type II Organic.
f. Paint 22, Paint Specification No. 22 Epoxy-Polyamide Paints (Primer,
Intermediate, and Topcoat).
g. SP 1, Solvent Cleaning.
h. SP 10, Near-White Blast Cleaning.
1.3 SUBMITTALS
A. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
B. Product Data:
1. Coal Tar Epoxy-polyamide:
a. Include Manufacturer's data sheet and MSDS sheets for the coating
system.
C. Test Reports:
1. Field Tests.
2. Coating Tests.
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0537-038-01 COATING OF MICROPILE CASING JANUARY 2023
3. Contractor shall submit test reports for the tests performed in shop and in the
field to Owner for review. At least 10 days prior to coating, submit sample
QC/Inspection forms that indicate compliance with test requirements specified
herein.
D. Certificates:
1. Coal tar epoxy-polyamide:
a. Submit certificate of compliance certifying that the coating system
meets the requirements specified herein.
1.4 ENVIRONMENTAL CONDITIONS
A. Start work only when ambient and curing temperatures are within limits of coating
manufacturer's recommendations and at least 5 DEGF above dew point
temperature.
1.5 SAFETY AND HEALTH PRECAUTIONS
A. Materials listed in this section contain coal tar pitch volatiles, which are toxic. Follow
safety procedures as recommended by manufacturer. Work in a well-ventilated
area. Provide, and require workers to use, impervious clothing, gloves, face shields
(8 IN minimum), and other appropriate protective clothing necessary to prevent eye
and skin contact with coating materials. Keep coatings away from heat, sparks, and
flame.
PART 2 - PRODUCTS
2.1 COATING SYSTEMS
A. Coal Tar Epoxy-Polyamide.
1. System: SSPC PS 11.01.
2. Primer: SSPC Paint 16, Black.
3. The coating shall be Bitumastic 300M COE, by Carboline Company, or Owner
approved equal that complies with the requirements specified herein.
4. Field coating shall be of the same type and manufacturer as used in shop
coating.
PART 3 - EXECUTION
3.1 CLEANING AND PREPARATION OF SURFACES
A. Solvent Cleaning:
1. SSPC SP 1. Remove visible oil, grease, and drawing and cutting compounds
by solvent cleaning.
B. Blast Cleaning:
1. SSPC SP 10. After solvent cleaning, complete surface preparation by near-
white blast cleaning. Remove residual dust from blasted surface by blowing
with dry, oil-free air, vacuuming, or sweeping. Provide surface profile of at
least 2 to 3 mils.
3.2 PROPORTIONING AND MIXING OF COATING SYSTEM
A. Proportioning and Mixing:
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1. Proportion and mix coating materials in accordance with the manufacturer's
recommendations and as described on the respective Product Data Sheets for
Marine/Offshore applications attached herewith.
3.3 COATING APPLICATION
A. General:
1. Apply primer coating to dry surfaces not more than 4 HRS after near-white
blast cleaning. Apply coats of each system so that finished surfaces are free
from runs, sags, brush marks and variations in color.
B. Application Method:
1. Apply coating using approved methods by the manufacturer and as allowed
for on respective product data sheets attached herewith. All coatings shall be
spray applied. Adhere to manufacturer’s specified coating times between
coats, with special attention given to maximum recoat times.
C. Repair of Defects:
1. Repair detected coating holidays, thin areas, and exposed areas damaged
prior to or during installation by surface treatment and application of
additional coating or by manufacturer's recommendations. Allow a period of
at least 72 HRS to pass following final coat before placing in contact with
ground.
a. Repair Procedure For All Coating Systems.
1) All coating surfaces damaged by handling, cutting, and welding
or in any other way damaged must be carefully and fully
repaired in accordance with these specifications and the coating
manufacturer's recommendations.
2) The damaged coating area and the bordering area 2 IN outside
the damaged area shall be removed by cutting a neat, uniform
perimeter with a wood chisel laid back at an angle of 45 DEG to
the surface and by abrasive blasting with a needle or pencil gun
(spot blast) to a near white metal SP-10). The adjacent
undamaged area of coating shall be protected during blasting
and subsequent coating operations.
3) As soon as practical after preparing the surface, it shall be
cleaned as previously described under surface preparation taking
care not to over spray undamaged coating. Recoating shall
begin immediately after cleaning and drying.
4) Areas of coating requiring additional thickness shall be re-coated
in strict accordance with manufacturer's instructions.
D. Coal Tar Epoxy-Polyamide System (Dry Film Thickness (DFT)):
1. Apply in two coats with each coat at a dry film thickness of not less than 8
mils. Provide total system minimum dry film thickness of 16 mils for coal tar
epoxy-polyamide system.
3.4 SURFACES TO BE COATED
A. Micropile casings required to be incorporated as a permanent part of the micropile.
3.5 COATING TESTS
A. Shop Tests:
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1. For testing dry film thickness, the procedures outlined in SSPC PA 2 shall be
followed.
2. When testing for holidays, test for holidays in the total coating system using a
wet-sponge holiday detector in accordance with the manufacturer's printed
instructions. Low voltage holiday detectors shall be used. Voltage settings
and procedures must be in strict accordance with NACE RPO 188-88.
B. Field Tests:
1. Holiday Testing:
a. Prior to installation, test for holidays in total coating system. Use a
low-voltage holiday detector of less than 90 volts in accordance with
manufacturer's instructions. After repair of holidays by surface
treatment and application of additional coating or by manufacturer's
recommendation, retest with a low-voltage holiday detector.
2. Dry Film Thickness:
a. After repair of holidays, measure dry film thickness using a magnetic
dry film thickness gage in accordance with ASTM D7091 and ASTM
E376. Re-measure after an additional coat is applied and add it to
meet minimum thickness requirements.
C. Owner Inspection and Testing:
1. In addition to the inspection and tests performed by the Contractor/Micropile supplier
(as applicable) for quality control, Owner may perform inspection and testing
for acceptance to the extent determined by Owner. The coating shall be
tested by Owner's testing agency before delivery to Owner and in the field
where applicable. The cost of such inspection and testing will be borne by
the Contractor if unsatisfactory coating is discovered, or by Owner if the
coating is satisfactory.
END OF SECTION
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SECTION 10 14 19
SAFETY SIGNS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section Includes:
Furnish all labor, materials, tools, equipment, and perform all work and services for
furnishing and installing safety signage as shown on the drawings and as specified.
Provide all supplementary or miscellaneous items, including connections and
mounting hardware, necessary for a sound, secure, and complete installation.
Related Sections:
Section 09 91 00,“Painting and Protective Coatings” for surface preparation and
coating system requirements.
Section 10 90 00,“Identification, Stenciling,and Tagging” for identification devices for
piping, valves, equipment and other items.
1.3ALLOWANCES
Except where specifically designated on the Drawings or in the Specifications, the type,
number and locations of signs shall be determined by the OWNER.
1.4REFERENCES
American National Standards Institute (ANSI):
A13.1 –Schemes for the Identification of Piping Systems
Z53.1 –Safety Color Code for Marking Physical Hazards
Federal Specification (FS):
L-P-387A(1) Plastic Sheet, Laminated, Thermosetting (For Designation Plates)
National Fire Protection Association (NFPA):
49-75 Hazardous Chemical Data
704-90 Standard System for the Identification of the Fire Hazards of Materials
Occupational Safety and Health Act (OSHA):
§1910.144 Safety Color Code for Marking Physical Hazards
§1910.145 Specifications for accident Prevention Signs and Tags
1.5SYSTEM DESCRIPTION
Safety signage shall be installed at non-potable water locations, equipment that
automatically starts, covers for rotating machinery, electrical control centers, fire fighting
apparatus locations, eye and noise protection, hazardous material locations, chlorine and
chemical areas, and other designated locations.
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1.6SUBMITTALS
Product Data:
Submit copies of manufacturer's technical brochure including color chart and list of
standard signs.
PRODUCTS
2.1MANUFACTURERS
Products: Subject to compliance with requirements, available products that may be
incorporated into the Work include, but are not limited to, the following available
manufacturers:
Brady Corporation, Milwaukee, WI
Seton Name Plate Corp., New Haven, CT
2.2SAFETY SIGNS
Plastic Signs (Type A):
60-mil rigid plastic for indoor/outdoor use, endures temperatures of -40°F to 176°F.
Rounded corners with mounting holes.
Signs, Self-Sticking (Type B):
Flexible 4-mil peel and stick vinyl for indoor/outdoor use, endures temperatures of -
40°F to 176°F.
Adhesive backingshall adhere quickly and firmly to smooth surfaces.
Fiberglass Signs (Type C):
Material: Multi-ply laminated fiberglass, minimum 0.100-inch thick, with guaranteed
not to chip, fade, rust, shatter or peel for 15 years.
Message encapsulated between two clear weather-resistant surface layers.
Indoor/outdoor use, endures temperatures of -40°F to 190°F and graffiti resistance.
Metal Signs (Type D):
Material: Silk-screened, baked enamel finish or synthetic film laminate, 0.040
aluminum panels.
Round-cornered andpunched for application to wall surfaces.
Painted Signs (Type E):
Stencils: Standard stencils prepared with letter sizes complying with
recommendations in ASMEA13.1. Minimum letter height is 1-1/4 inches for ducts,
and 3/4 inch for access door signs and similar operational instructions.
Material: Fiberboard.
Stencil Paint: Exterior, oil-based, alkyd-gloss black enamel, unless otherwise
indicated. Paint may be in pressurized spray-can form.
Identification Paint: Exterior, oil-based, alkyd enamel in colors according to
ASMEA13.1, unless otherwise indicated.
Exit Signs (Type F):
Material: Plastic, 1/8-inch (minimum) thickness.
Description: 6-inch high, 3/4-inch stroke, red letters on white background.
Illumination: As required by applicable jurisdictional agency fire code.
Available Manufacturers:
Brady Corporation, Milwaukee, WI
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Seton Name Plate Corp., New Haven, CT
Safety Sign Message:
Consists of two parts; the OSHA Heading and the Specific Message.
OSHA Heading will consist of one ofthe following:
DANGER. White letters on red oval surrounded by a rectangular black field.
NOTICE. White letters on a blue field.
SAFETY FIRST. White letters on a green field.
CAUTION. Yellow letters on a black field.
RADIATION. Yellow letters on a purple field.
THINK. White letters on a green field.
BE CAREFUL. White letters on a green field.
Safety signs shall comply with the requirements of OSHA 1920.145 with respect to
size, color, and symbols.
Information regarding message, location, and related items shallbe shown on the
Drawings or in the Sign Schedule at END OF SECTION.
All sign attachment and mounting hardware shall be Type 316 stainless steel. Each sign
shall utilize 4 screws or 2 brackets.
EXECUTION
3.1EXAMINATION
Examine areas and conditions, with Installer present, for compliance with requirements for
maximum moisture content, installation tolerances, and other conditions affecting
performance of the Work.
Proceed with installation only after unsatisfactory conditions have been corrected.
3.2APPLICATIONS
Safety Signage: Provide and install at the following locations as applicable:
Non-potable Water Faucets: CAUTION/Do Not Drink Water.
Automatic Equipment Operation: CAUTION/Equipment Starts and Stops Automatically.
Electrical Entrance and FenceSurrounding Electrical Equipment: DANAGER/ High
Voltage.
Eye Wash Station: EMERGENCY/ Eye Wash Station Keep Area Clean.
Safety Shower: EMERGENCY/ Safety Shower Keep Area Clean.
Fence Surrounding Property: Notice/No Trespassing.
Adjacent to Vertical Ladders: SAFETY FIRST/Remember Wear Safety Harness.
Visitors: NOTICE/All Visitors Must Register at Office.
Visitor Parking:
No Smoking: At designated locations.
Warning Labels: Apply warning labels to equipment, machinery, electrical equipment,
storage containers, and related items to the items as designated below. Label size shall be
according to the space available. Do not apply label to concrete or masonry surfaces, use
Type A or C signs.
Electrical Disconnects: DANAGER/480 Volts (Provide correct voltage or use High
Voltage).
Equipment Belt Guards: CAUTION/Keep Guard in Place.
Flammable Material Storage: Flammable Liquids.
Chemical and HazCom:
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Chemicals: Place NFPA Signs on chemical storage tanks, adjacent to chemical pumps,
and related items communicating thefollowing information:
Health Hazard.
Fire Hazard.
Specific Hazard.
Instability Hazard.
Type: Depending on application sign shall be self-adhesive vinyl (Type B) or
fiberglass (Type C).
3.3SIGN SCHEDULE
Safety Signs: In addition to paragraph 3.2 above, referto Safety Sign Schedule following the
“End Of Section” for other applications.
END OF SECTION
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SECTION 1090 00
IDENTIFICATION, STENCILING, ANDTAGGING
GENERAL
1.1WORK INCLUDED
The CONTRACTOR shall furnish all labor, materials, tools, equipment, and perform all work
and services for all identifications, stenciling and tagging as shown on the drawings and as
specified.
Items include but are not necessarily limited to the following areas of work:
Paint and provide identification signs for all exposed piping, ductwork, and conduits in
accordance with Schedule A at the end of this section.
Provide identification tags and stenciling for all equipment, valves, instrumentation,
and electrical components, including existing equipment and valves. Specific valve
and equipment tag information shall be furnished by the OWNER.
Although such work is not specifically shown or specified, all supplementary or
miscellaneous items, including connections and mounting hardware, necessary wfor a
sound, secure, and complete installation shall be furnished and installed as part of this work.
1.2QUALITY ASSURANCE
Unless otherwise specified, all equipment and valves including mechanical, process,
electrical, and instrumentation are required to be identified.
Unless otherwise specified, openings, accesses and related locations are required to be
identified.
Coordination, development, and initiation of identification, marking, and tagging systems
and determination of separation of subcontractor's and manufacturer's corresponding
responsibilities is the sole responsibility of the CONTRACTOR.
Referenced Standards: Comply with applicable provisions and recommendations of the
following, except where otherwise shown or specified:
ANSI A13.1, Scheme for the Identification of Piping Systems.
Great Lakes -Upper Mississippi River Board of State Sanitary Engineers (Ten States
Standards). Recommended Standards of Waste Treatment Works latest edition,
Recommended Color Scheme for Piping. Three Great Lakes -Upper Mississippi River
Board of State Sanitary, 1968 Edition, Addendum No.6, Painting of Water Works
Piping for Public Water Supplies.
OSHA 1910.144, Safety Color Code for Marking Physical Hazards.
SSPC Volume 2, System and Specifications, Surface Preparation Guide and Paint
Application Specifications.
1.3SUBMITTALS
Submit identification register acknowledging all designated or scheduled equipment,
instruments, gauges, valves, HVAC equipment, mechanical and electrical equipment. All
items on register shall be tagged. Numbering system will be as shown on P&ID drawings.
Develop and submit full identification register acknowledging equipment, valves,
instruments, mechanical equipment and electrical equipment which is not designated or
scheduled in drawings and specifications. Provide identifications compatible but not
conflicting with designated or scheduled equipment and related items. All items on register
shall be tagged.
Submit assurances that subcontractors and manufacturers have been advised of register
requirements.
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Update identification register immediately prior to final acceptance of work.
Pipe Markers and Safety Signs:
Submit for approval samples of each type of marker and sign specified.
Submit copies of manufacturer's technical brochure including color chart and list of
standard signs.
PRODUCTS
2.1MATERIALS
Acceptable Manufacturers: Provide products by one of the following:
Brady Corporation.
Seton Identification Products.
Or approved equal.
General:
Pipe marker and safety sign materials shall withstand normal washing as required to
remove grease, oil, chemicals, etc., without showing discoloration, loss of gloss,
staining or other damage.
Piping markers shall be formed from laminated plastic. All printing shall be sealed
with a formed butyrate plastic film. Markers for piping up to 6-inch diameter shall be
pre-formed to completely wrap around the pipe requiring no adhesive. Markers for
pipes over 6-inch diameter shall be performed to the contour of the pipe and attached
with stainless steel spring fastener.
Each marker shall consist of at least one legend descriptive of the function of the
pipe, as listed in Schedule A, and a directional arrow.
The size of lettering and marker shall conform to ANSI A13.1.
Location of markers:
Adjacent to each valve and "T" connection.
At each branch and riser takeoff.
At each pipe passage through a wall, floor and ceiling.
On all horizontal and vertical pipe runs at 20-foot intervals.
Safety signs shall be 18 inches by 24 inches formed from semi-rigid butyrate or
polyethylene. They shall be attached with 4 stainless steel screws or similar fastener
for substrate.
2.2COLORS AND FINISHES
Color Schedule: Paint colors will be selected by the ENGINEER from the approved
manufacturer's color chips.
Color Coding: In general, all color coding of piping, ducts and equipment shall comply with
applicable standards of ANSI A13.1 and OSHA 1910.144and shall meet the TCEQ
requirements of 30 TAC 217.
Piping and Sign Color Code: Refer to Schedule A at end of section.
2.3IDENTIFICATION SYSTEMS
Tagging system and stenciling system shallbe selected by the CONTRACTOR. Valve tags
shall include identification number, process, valve type, direction to open and number of
turns to open.
Tagging of Equipment:
Yard Valves: Identify with brass marking plate (minimum 1/8-inch thick) with
embedment for placement in concrete.
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Yard Slide Gates: Provide stainless steel plates with black enamel filled embossed
lettering. Provide minimum plate of 2-1/2 inches with minimum letter height of
2inches. Attach to gate frames at visible location by stainless steel fasteners.
Process valves, mechanical valves, instrumentation, and mechanical and process
equipment (interior/exterior):
Provide minimum 2-1/2-inch stainless steel plate with black enamel filled
lettering.
Attachto valves by nylon strap or stainless steel nonremovable beaded chains
or to equipment by stainless steel fasteners.
Provide general color scheme of tagging for listed items with black letter and
numbers on background as follows:
Instrumentation tagsWhite
Process valves and equipment tagsRed
Water valves tagsBlue
Mechanical valve and equipment tagsGreen
Electrical equipmentYellow
Electrical Equipment: Observe requirements and provisions stated in Division26of
these specifications.
Identification of piping, process tanks, galleries, pits, chemical liquid or solid storage tanks
and silos, storage vessels, air ducts and similar items.
Use Tagging Systems by W. H. Brady Company, as follows:
Vinyl film cloth for interior non-insulated piping systems (CategoryB-500).
Thin film for insulated piping systems (Category B-350).
All weather film for outdoor exposed piping (Category B-350). Provide flow
arrows, banding tape, and numbering and lettering of same materials for
corresponding applications.
Use stenciling systems in accordance with accepted practices.
Tagging and stenciling letter and number heights shall be:
Minimum 1/2 inch for piping less than 1-inch diameter.
Minimum 1-1/8 inches for piping 1 inch to 3-inch diameter.
Minimum 2-1/4 inches for piping greater than 3-inch diameter to 24-inch.
Minimum 3-1/2 inches for piping greater than 24-inch diameter and all process
tanks, galleries, pits, chemical, liquid, or solid storage tanks and silos, storage
vessels, mechanical heat exchangers, ducts, blowers, and similar related items.
EXECUTION
3.1INSTALLATION
Protected printed surfaces and adjacent work and materials by suitable covering during
progress of work.
Insurehardware, accessories, plates, fixtures, finished work and similar items are removed
or protected.
Paint or apply not less than one band on any length of pipe. Follow a clean-cut line around
entire pipe.
Install piping markers and safety signs only after all painting and finish work has been
completed. This does not include temporary "wet paint" or construction safety signs.
Provide arrows and identification stickers:
At 20'-0" maximum centers along continuous lines.
At changes in direction (route), valves, risers, joints, machinery, or equipment.
Where pipes, ducts pass through floor, wall, ceiling, cladding assemblies and the like
obstruction on both sides of assembly.
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Apply markers on both sides of pipe and where view is not obstructed.
Arrow markers must point away from pipe markers and in flow direction, if flow in
both directions use double-headed arrow markers.
Identify piping and ductwork including interior or exterior, exposed or covered, insulated or
not, including pipes and ducts in open or covered floor or ceiling ducts or spaces.
Apply tapes in uniform manner and parallel to piping and ducts.
SCHEDULE A
PIPING AND SIGN COLOR CODE
Piping LetteringBackground
Piping and LegendColor Color Color
Water
Raw WaterTanBlack Yellow
Air Conditioning WaterBlueWhiteGreen
Domestic Hot WaterBlue w/Black Yellow
6” Red Bands
Plant Water/ReclaimedPurpleBlackGreen
Potable WaterLight BlueBlackGreen
Effluent after clarificationDark GreenBlackGreen
Air and Gas
Blower AirGreenWhiteBlue
Chlorine GasYellow Yellow Black
Compressed AirLight Green Yellow Black
Instrument AirLight Green w/______________
Dark Green Bands
Mixed GasRedBlack Yellow
Natural GasRedBlack Yellow
Propane GasRed Black Yellow
Sulfur DioxideLime Green Black Yellow
w/ Yellow Bands
Sludge Gas, HPRedBlack Yellow
Sludge Gas, LPRedBlack Yellow
Waste GasRedBlack Yellow
Blower LubeWhiteWhiteBlue
GreaseWhiteBlackGreen
Foul (odorous) AirBeige Yellow Black
Oxygen GasN/AGreenWhite
Ozone Stainless Steel w/
White Bands
Chemicals
Aluminum Sulfate (Solution)Yellow w/Black Yellow
Green Bands
Aluminum Sulfate (Liquid)Yellow w/Black Yellow
Orange Bands
Chlorine LiquifiedYellow Black Yellow
Chlorine SolutionYellow Black Yellow
Ferric ChlorideLight Brown w/ Black Yellow
Red Bands
Ferric SulfateLight Brown w/_____________
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Yellow Bands
Ferric Sulfide Yellow Black Yellow
Ferrous Chloride Yellow Black Yellow
Sodium Hypochlorite Yellow Black Yellow
Sulphur Dioxide Lime Green w/ Black Yellow
Yellow Bands
Polymer White w/ ______ _______
Green Bands
Process
Grit Brown Black Green
Groundwater Drain Tan White Black
Drain Green Black Green
Scum Brown Brown Green
Sewage Gray Black Green
Sludge Brown Black Green
Digester Tank Vent Brown Black Green
Oxygenated Wastewater Grey White Green
Vents
High and Low Yellow Black Yellow
Temperature
Colors listed above shall be similar to the following standard colors by Tnemec Company:
Light Blue: 17BL “Horizon Blue”
Blue: 59HT "Safety Blue"
Red: 06SF "Safety Red"
Gray: 33GR " Gray"
Green: BS28 "Safety Green"
Lime Green:46GN “Limeade”
Light Green 09SF “Spearmint/Safety Green”
Tan: TRA Twine (Tan) (Tnemec has on file)
Yellow: 02SF "Safety Yellow"
White: 00WH "White"
Purple: 13SF “Purple Mountain’s Majesty”
Brown: TRA Outside Equipment Brown (Tnemec has on file)
Light Brown: 06BR “Amber Canyon”
END OF SECTION
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SECTION 26 00 00
ELECTRICAL GENERAL PROVISIONS
PART 1 - GENERAL
1.1!RELATED DOCUMENTS
A.!Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
1.2!SUMMARY
A.!The work includes, but is not limited to, the following principal systems and equipment:
1.!Motors.
2.!Grounding and Lightning Protection.
3.!208/120 V distribution.
4.!Panelboards.
5.!Raceways.
6.!Transformers.
7.!Lighting fixtures and lamps.
8.!480-V distribution.
9.!Miscellaneous control.
10.!480-V motor control centers.
11.!Variable Frequency Controllers.
1.3!REFERENCE STANDARDS
A.!Perform work, furnish and install materials and equipment in full accordance with the latest
issue of the applicable rules, regulations, requirements, and specifications of the following:
1.!Local laws and ordinances.
2.!State and Federal Laws.
3.!National Electrical Code (NEC).
4.!State Fire Marshal.
5.!Underwriters' Laboratories (UL).
6.!National Electrical Safety Code (NESC).
7.!American National Standards Institute (ANSI).
8.!National Electrical Manufacturer's Association (NEMA).
9.!National Electrical Contractor's Association (NECA) Standard of Installation.
10.!Institute of Electrical and Electronics Engineers (IEEE).
11.!Insulated Cable Engineers Association (ICEA).
12.!Occupational Safety and Health Act (OSHA).
13.!National Electrical Testing Association (NETA).
14.!American Society for Testing and Materials (ASTM).
B.!Wherever the requirements of the Specifications or Drawings exceed those of the above
items, the requirements of the Specifications or Drawings govern. Code compliance is
mandatory.
C.!Product Quality: All electrical items shall be new and unused. Items such as cables,
transformers, motors, control centers, etc., shall be newly manufactured for this project.
Proof of purchase documents shall be provided upon request. Utilize products of a single
MANUFACTURER for each item.
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1.4!CONTRACT DOCUMENTS
A.!Intent:
1.!The intent of the contract drawings or Plans is to establish the types of systems and
functions; the drawings will not specifically indicate each item essential to the
functioning of the system.
2.!Electrical drawings are generally diagrammatic and show approximate location and
extent of work.
3.!Install the work complete, including minor details necessary to perform the function
indicated.
4.!In case of doubt as to work intended, or if amplification or clarification is needed,
request instructions from the ENGINEER.
5.!It is also the intent of these Contract Documents that the electrical and process
system CONTRACTOR coordinate with each other in order to provide a complete and
workable system with all wiring, conduit and accessories required which may not be
shown on the Plans.
B.!Discrepancies:
1.!Review pertinent drawings and adjust the work to conditions shown.
2.!Where discrepancies occur between Plans, Specifications, and actual field conditions,
immediately notify the ENGINEER for his interpretation.
3.!Dimensions on electrical drawings shall be verified with structural, architectural and
mechanical drawings.
C.!Outlet and Equipment Locations:
1.!Coordinate the actual locations of electrical outlets and equipment with building
features and mechanical equipment as indicated on architectural, structural and
mechanical drawings.
2.!Review with the ENGINEER any proposed changes in outlet or equipment location.
3.!Relocation of outlets before installation, up to 3 feet from the position indicated, may
be directed by OWNER without additional cost.
4.!Remove and relocate outlets placed in an unsuitable location, when so requested by
the ENGINEER.
1.5!REGULATIONS AND PERMITS
A.!Regulations: Work, materials and equipment must comply with the latest rules and
regulations of the following:
1.!National Electrical Code (NEC).
2.!National Electrical Safety Code (NESC).
3.!Occupational Safety and Health Act (OSHA).
4.!State and federal codes, ordinances and regulations.
5.!Local Electrical Code.
B.!Discrepancies:
1.!The Plans and Specifications are intended to comply with listed codes, ordinances,
regulations and standards.
2.!Where discrepancies occur, immediately notify the ENGINEER in writing and ask for
an interpretation.
3.!Should installed materials or workmanship fail to comply, the CONTRACTOR is
responsible for correcting the improper installation.
4.!Additionally, where sizes, capacities, or other such features are required in excess of
minimum code or standards requirement, provide those specified or shown.
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0537-038-01 ELECTRICAL GENERAL PROVISIONS JANUARY 2023
1.6!CONTRACTOR QUALIFICATIONS
A.!An acceptable CONTRACTOR for the work under this division must have personnel with
experience, training, and skill to provide a practical working system. The CONTRACTOR shall
have previous water and wastewater experience with at least five years in business.
1.!The CONTRACTOR shall be required to furnish acceptable evidence of having installed
not less than three systems of size and type comparable to this project.
2.!The systems must have served satisfactorily for not less than three years.
3.!The superintendent must have had experience in installing not less than three
systems.
4.!The CONTRACTOR shall submit qualifications of his firm and resumes of his personnel
who will work on this project.
1.7!GENERAL REQUIREMENTS FOR WORKMANSHIP, EQUIPMENT AND MATERIALS
A.!All electrical work shall be performed by workers skilled in the electrical trade and licensed
for the work by the local authority.
B.!A licensed Master Electrician will be required for constructing, installing, altering,
maintaining, repairing or replacing any electrical wiring, apparatus, or equipment on any
voltage level. A licensed Master Electrician or a licensed Journeyman Electrician is required
to be on the job site during the performance of any electrical work.
C.!All cable splicing methods and materials shall be of the type recommended by the splicing
materials MANUFACTURER for the cable to be spliced and shall be approved by the
ENGINEER prior to installation.
D.!All materials and equipment shall be installed in accordance with the approved
recommendations of the MANUFACTURER and the best practices of the trade, and in
conformance with the Contract Documents. The CONTRACTOR shall promptly notify the
OWNER in writing of any conflict between any requirements of the Contract Documents and
MANUFACTURER's directions and shall obtain written instructions from the OWNER before
proceeding with the work. Should the CONTRACTOR perform any work that does not comply
with the MANUFACTURER's directions or such written instructions from the OWNER, he shall
bear all costs incurred in correcting deficiencies.
E.!All equipment and materials shall be new, unless specifically noted otherwise, and shall bear
the MANUFACTURER's name, trademark and ASME, UL, or other labels in every case where
a standard has been established for the particular item. Equipment shall be the latest
approved design of a standard product of a MANUFACTURER regularly engaged in the
production of the required type of equipment and shall be supported by a service
organization that is, in the opinion of the OWNER, reasonably convenient to the site.
F.!It is the responsibility of the CONTRACTOR to ensure that items furnished fit the space
available with adequate room for proper operation and maintenance. He shall make
measurements to ascertain space requirements, including those for connections, and shall
furnish and install such sizes and shapes of equipment that, in the final inspection, will suit
the true intent and meaning of the Plans, Specifications and Contract Documents.
G.!The CONTRACTOR shall furnish and install all equipment, accessories, connections and
incidental items necessary to complete the work, ready for use and operation by the
OWNER.
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H.When the ENGINEER has reviewed equipment submittals and given instructions to proceed
with the installation of items of equipment that require arrangements or connections
different from those shown on the drawings, it shall be the responsibility of the
CONTRACTOR to install the equipment to operate properly and in accordance with the intent
of the Plans and Specifications, and he shall provide any additional equipment and materials
that may be required. The CONTRACTOR shall be responsible for the proper location of
roughing-in and connections by other trades. All changes shall be made at no increase in the
Contract Amount or additional costs to other trades.
I.The CONTRACTOR shall support the installation of all equipment, plumb, rigid and true to
line. The CONTRACTOR shall determine how equipment, fixtures, conduit, etc., are to be
installed, and shall provide foundations, bolts, inserts, stands, hangers, brackets and
accessories for proper support whether or not shown on the drawings.
1.8SHOP DRAWINGS AND PRODUCT DATA
A.Data Required:
1.Submit shop drawings, product data and all other required information as specified in
Division 1 General Requirements. Submittals are required on all products and items to
be installed on this project.
2.Submittal data must show MANUFACTURER's name, published ratings or capacity
data, detailed equipment drawing for fabricated items, panel diagrams, wiring
diagrams, installation instructions and other pertinent data.
3.Where literature is submitted covering a group or series of similar items, the
applicable items must be clearly indicated.
4.Submittal Items: Submittals are required for all equipment and materials to be used
on this project. Submittals shall be complete with all pertinent information and
installation details.
5.Terminal Connection Diagrams:
6.Submit terminal connection diagrams for approval prior to any wire installation.
7.Submit finalized terminal connection diagrams at the end of the Contract.
1.9SYSTEM RESPONSIBILITY
A.TheELECTRICALCONTRACTOR shall be responsible for:
1.Complete systems in accordance with the intent of these Contract Documents.
2.Coordinating the details of facility equipment and construction for all Specification
Sections which affect the work covered under Division 26, Electrical.
3.Furnishing and installing incidental items not actually shown or specified, but which
are required by good practice to provide complete functional systems.
4.Coordinate the work with the PLANT CONTROL SYSTEM INTEGRATOR.
The PLANT CONTROL SYSTEM INTEGRATORshall furnish and install the
primary and secondary instruments, i.e., level elementand level indicating
transmitter, flow transmitter (flow tube by others), headloss transmitters, etc.
Refer to Loop Drawings.
The conduit and wiring to and from the instruments shall be furnished and
installed by the ELECTRICALCONTRACTOR. Termination in the instrument shall
be by PLANT CONTROL SYSTEM INTEGRATOR.
All terminations in the control panel shall be by PLANT CONTROL SYSTEM
INTEGRATOR.
ELECTRICALCONTRACTOR shall:
Provide termination drawings for PLANT CONTROL SYSTEM INTEGRATOR.
Provide equipment pad for control panels, consoles and instrument panels
shall be furnished by the Electrical CONTRACTOR.
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Coordinate testing of the electrical system being furnished and shall be
responsible for the equipment supplied.
Present at time of the instrument system testing and start-up and
responsible for the coordination of the facility testing with the PLANT
CONTROL SYSTEM INTEGRATOR.
Coordinate the interface requirement between each starter and control
panel furnished under this Contract with the PLANTCONTROL SYSTEM
INTEGRATOR.
Written proof shall be furnished to verify a clear understanding has been
reached between the ELECTRICALCONTRACTOR and the PLANT CONTROL
SYSTEM INTEGRATORfor each control loop requirement, i.e., type of contacts
(momentary, maintained), interface relay requirement, number of wires,
terminal marking, control schematic information, and wiring diagrams.
B.Electrical Drawings showed only general locations of equipment, devices, and raceway,
unless specifically dimensioned. The CONTRACTOR shall be responsible for the proper
routing of raceway, subject to the approval of the ENGINEER.
C.Submit to the ENGINEER in writing details of any necessary, proposed departures from
these Contract Documents. Submit such request as soon as practicable,and within ten (10)
days after award of the Contract. Make no such departures without written approval of the
ENGINEER.
D.Dimensions on electrical drawings shall be verified with structural, architectural, and
mechanical drawings.
E.Where the CONTRACTOR is submitting a packaged system; the system shall comply with the
requirements of the electrical specifications, including field cables, conduits, junction boxes,
circuit breakers, combination starters, pushbuttons, pilot lights, and motors. Deviations shall
not be accepted, unless pre-approved. Control centers and special control cabinets wired to
terminal blocks shall include the MANUFACTURER's standard quality, unless specifically
mentioned to the contrary on the drawings or in the specifications.
F.Maintain continuity of electric service to functioning portions of the process or buildings
during hours they are normally in use. Temporary outages will be permitted during cutover
work at such times and places as can be pre-arranged with the ENGINEER and OWNER.
Such outages shall be kept to a minimum number and minimum length of time. Make no
outages without prior written authorization of the ENGINEER. Include costs for temporary
wiring and overtime work required in the Contract price. Remove temporary wiring at the
completion of the work.
PART 2 -PRODUCTS
2.1PRODUCT REQUIREMENTS
A.Condition: Materials and equipment provided under these Specifications shall be new
products of MANUFACTURERs regularly engaged in production of such equipment. Provide
the MANUFACTURER's latest standard design for the type of equipment specified.
B.NEC and UL: Products must conform to requirements of the National Electrical Code. Where
Underwriters' Laboratories have set standards, listed products, and issued labels, products
used must be listed and labeled by UL.
C.Space Limitations: Equipment selected must conform to the building features and must be
coordinated with them. Do not provide equipment which will not suit arrangement and
space limitations.
D.Factory Finish: Equipment must be delivered with a hard surface, factory-applied finish so
that no additional field painting is required.
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0537-038-01ELECTRICAL GENERAL PROVISIONSJANUARY 2023
E.!Field Installation: All field installed equipment, conduit, etc., shall require Type 316 stainless
steel nuts, bolts, washers, and rigid aluminum or Type 316 stainless steel metal framing and
supports, and other items as indicated on the Plans.
2.2!SUBSTITUTIONS
A.!Refer to Division 1 General Requirements for substitution requirements.
PART 3 - EXECUTION
3.1!PROTECTION OF EQUIPMENT
A.!Moisture:
1.!During construction, provide heaters to protect switchgear, transformers, motors,
control equipment, and other items from moisture absorption and corrosion.
2.!Apply protection immediately on receiving the products and provide continuous
protection.
3.!Store all equipment indoors in dry, well ventilated and heated space.
B.!Clean: Keep products clean by elevating above ground or floor and by using suitable
coverings.
C.!Damage: Take such precautions as are necessary to protect apparatus and materials from
damage. Failure to protect materials is sufficient cause for rejection of the apparatus or
material in question.
D.!Finish: Protect factory finish from damage during construction operations and until final
acceptance of the project.
3.2!INSTALLATION
A.!Cooperation with Other Trades:
1.!Cooperation with trades of adjacent, related or affected materials or operations, and
of trades performing continuations of this work under subsequent contracts, is
considered a part of this work to effect timely and accurate placing of work and to
bring together, in proper and correct sequence, the work of such trades.
2.!Coordinated equipment layout in sufficient time to be coordinated with work of
others, provide drawings and layout work showing exact size and location of sleeves,
openings or inserts for electrical equipment in slabs, walls, partitions and chases.
B.!Workmanship: Work must be performed by workers skilled in their trade. The installation
must be complete whether the work is concealed or exposed.
C.!Concrete Equipment Pads:
1.!Install minimal 4-inch thick concrete foundation pads for indoor floor mounted
equipment, except where direct floor mounting is permitted by the ENGINEER.
2.!Pour pads on roughened floor slabs, sized so that outer edges extend a minimum of 3
inches beyond equipment.
3.!Trowel pads smooth and chamfer edges to a 1-inch bevel.
4.!Provide dowels in slab, and rebar between the dowels.
5.!Pads must drain away from the equipment.
6.!Secure equipment to pads as recommended by the MANUFACTURER.
D.!Setting of Equipment:
1.!Equipment must be leveled and set plumb.
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2.!Sheet metal enclosures mounted against a wall must be separated from the wall not
less than 1/2 inch by means of corrosion resistant spacers or by 3 inches of air for
freestanding units.
3.!Use corrosion resistant bolts, nuts and washers to anchor the equipment.
E.!Sealing of Equipment:
1.!Permanently seal outdoor equipment at the base using grout in accordance with
Division 3 Section 03 60 00 "Grout, Non-Shrink."
2.!Seal or screen openings into equipment to prevent entrance of animals, birds and
insects.
3.!Use stainless steel or copper mesh with openings not larger than 1/16-inch squares
for screened openings.
4.!Seal small cracks and openings from the inside with silicone sealing compound.
F.!Concealed Work: Conceal electrical work in walls, floors, chases, under floors, underground
and above ceilings except:
1.!Where shown or specified to be exposed. Exposed is understood to mean open to
view.
2.!Where exposure is necessary to the proper function.
3.!Where size of materials and equipment precludes concealment.
G.!Application: Unless otherwise indicated, power will be utilized as follows:
1.!Motors 1-2 horsepower and smaller: 120 V, single-phase.
2.!Incandescent lighting, convenience outlets, special outlets and fluorescent lighting:
120 V, single-phase.
3.3!EQUIPMENT AND DEVICE MARKING
A.!Nameplates:
1.!Externally mark electrical equipment by means of suitable nameplates identifying each
and the equipment served.
2.!Provide each piece of equipment with a black phenolic nameplate with 3/16-inch high
white lettering secured to front of equipment. For nameplate size, refer to Section 26
05 53 "Identification for Electrical Systems."
3.!Supply blank nameplates for spare units and used spaces.
4.!Actual nameplate legend, which may consist of up to three lines, will be provided to
the ENGINEER on submittals.
B.!Nameplate Fasteners: Fasten nameplates to equipment only by means of appropriate
noncorroding screws and as specified in Section 26 05 53 "Identification for Electrical
Systems."
C.!Nameplate Information: In general, the following information is to be provided for the types
of electrical equipment as listed.
1.!Switchgear, Motor Control Centers and Distribution Panelboards: On the mains,
identify the piece of equipment, the source and voltage characteristics, i.e., 480 V,
3PH, 3 W, etc. For each branch circuit protective device, identify the load served.
2.!Transformers: Identify the service source and load served.
3.!Panelboards: Identify the service source, panelboard designation and voltage
characteristics.
D.!Panelboards:
1.!Prepare a neatly typed circuit directory behind clear heat-resistant plastic for each
panelboard.
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0537-038-01 ELECTRICAL GENERAL PROVISIONS JANUARY 2023
2.!Identify circuits by equipment served and by room numbers, where room numbers
exist.
3.!Use equipment names and room numbers selected by the ENGINEER; names and
numbers may be different from those shown on Drawings.
4.!Indicate spares and spaces with light, erasable pencil markings.
E.!Boxes, Small Equipment and High Equipment:
1.!Pull boxes and similar items may be marked with Dymo No. 158-4 vinyl embossing
tape with adhesive back in lieu of nameplates. Use Dymo No. 7123 perma-stick liquid
adhesive with the tape. Tape color, placement and spacing must be approved by the
ENGINEER before starting this work. Individually mounted disconnect switches and
motor starters shall be marked with phenolic nameplates attached with stainless steel.
2.!Provide identification stencils for high voltage equipment and raceways with the
legend "DANGER HIGH VOLTAGE." Mark all exposed high voltage raceways every 25
feet.
F.!Power Receptacles: Use nameplate or engraved plate to identify power receptacles where
the nominal voltage between a pair of contacts is greater than 150 V with circuit No.,
voltage and phases.
G.!Wall Switches: Engrave the switch plate of the switch with the function of the switch.
3.4!TESTING
A.!Test Conditions:
1.!Place circuits and equipment into service under normal conditions, collectively and
separately, as may be necessary to determine satisfactory operation.
2.!Perform specified tests in the presence of the ENGINEER, as specified in the various
sections of the specifications.
3.!Furnish all instruments, wiring, equipment and personnel required for conducting
tests.
4.!Demonstrate that the equipment operates in accordance with requirements of the
Specifications and Drawings.
B.!Test Dates: Schedule final acceptance tests sufficiently in advance of the Contract
completion date to permit completion of any necessary adjustment or alterations within the
number of days allotted for completion of the Contract.
C.!Retests: Conduct retests as directed by the ENGINEER of such time duration as may be
necessary to assure proper functioning of adjusted or altered parts or items of equipment.
Any delay due to necessary retests does not relieve the CONTRACTOR of his responsibility
under this contract.
3.5!PROJECT RECORD DOCUMENTS
A.!Prepare and maintain Project Record Documents in accordance with Division 1 Section 01 78
10 "Project Record Documents" and the following:
1.!At the job site, maintain a set of white prints of the contract drawings.
2.!At the job site, maintain a set of equipment terminal connection diagrams.
3.!On the prints, record field changes and diagrams of those portions of work in which
actual construction is at variance with the contract drawings.
4.!Mark the drawings with a colored pencil. Record installed feeder conduits,
dimensioning the exact location and elevation of the conduit.
B.!Delivery: Submit Project Record Documents in accordance with Division 1 Section 01 78 10
"Project Record Documents."
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3.6!CUTTING AND PATCHING
A.!Lay out work carefully in advance. Do not cut or notch any structural member or building
surface without specific approval of ENGINEER. Carefully carry out any cutting, channeling,
chasing, or drilling of floors, walls, partitions, ceilings, paving, or other surfaces required for
the installation, support, or anchorage of conduit, raceways, or other electrical materials and
equipment. Following such work, restore surfaces neatly to original condition.
3.7!LOAD BALANCE
A.!The Drawings and Specifications indicate circuiting to electrical loads and distribution
equipment. Balance electrical load between phases as nearly as possible on switchboards,
panelboards, motor control centers, and related items.
3.8!MOTOR ROTATION
A.!Before and after final service connections are made, check and correct the rotation of
motors.
B.!Coordinate rotation checks with the ENGINEER and the CONTRACTOR responsible for the
driven equipment. Submit a written report to the ENGINEER for each motor verifying that
rotation has been checked and corrected.
3.9!CLEANING AND TOUCH-UP PAINTING
A.!Touch up scratches, scrapes, or chips in interior and exterior surfaces of devices and
equipment with finishes matching, as nearly as possible, the type, color, consistency, and
type of surface of the original finish. If extensive damage is done to equipment paint
surfaces, refinish the entire equipment in a manner that provides finish equal to or better
than the factory finish, and that meets the requirements of the Specifications and is
acceptable to the ENGINEER.
END OF SECTION
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0537-038-01 ELECTRICAL GENERAL PROVISIONS JANUARY 2023
SECTION 26 05 05
SELECTIVE DEMOLITION FOR ELECTRICAL
PART 1 - GENERAL
1.1!SCOPE OF WORK
A.!Furnish, install and test all equipment, wiring and appurtenances as may be required to
perform the electrical demolition shown on the Drawings and as specified herein.
1.2!SCHEDULES
A.!Schedule with the Owner/Engineer for required shutdowns to accommodate system
demolition and installation of temporary facilities.
1.3!STANDARDS
A.!Temporary wiring of systems to maintain operation of facilities while undergoing
modifications and demolition shall be provided in accordance with:
B.!American National Standards Institute / National Fire Protection Association (ANSI/NFPA),
No. 70.
C.!National Electrical Code (NEC), Article No. 590 Temporary Wiring.
1.4!QUALITY ASSURANCE
A.!Verify field measurements and circuiting arrangements are as shown on the Drawings.
B.!Verify that abandoned wiring and equipment serve only abandoned facilities.
C.!Demolition drawings are based on casual field observation and existing record documents.
Discrepancies shall be reported to the Owner/Engineer before disturbing the existing
installation.
D.!By beginning demolition, the Contractor accepts the existing conditions and warrants that he
will maintain service to equipment and items not scheduled or indicated for removal.
PART 2 - PRODUCTS
2.1!MATERIALS AND EQUIPMENT
A.!Materials and equipment for patching and extending work: As specified in individual
Sections.
2.2!DESIGN AND CONSTRUCTION
A.!If temporary electrical wiring and facilities are required, the Contractor shall provide such
wiring and facilities to comply with the NEC.
PART 3 - EXECUTIONS
3.1!PREPARATION
A.!Disconnect electrical systems in walls, floors and ceilings scheduled for removal.
B.!Coordinate utility service outages with the Utility Company to provide continuous service to
operating equipment.
C.!Provide temporary wiring and connections to maintain existing systems in service during
construction. When work must be performed on energized equipment or circuits, use
personnel experienced in such operations.
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D.!Existing Electrical Service: Maintain existing system in service until new system is complete
and ready for service. Disable system only to make switchovers and connections. Obtain
permission from the Owner/Engineer at least one week in advance, before partially or
completely disabling system.
3.2!DEMOLITION AND EXTENSION OF EXISTING ELECTRICAL WORK
A.!Remove, relocate and extend existing installations to accommodate new construction.
B.!Remove abandoned wiring to source of supply.
C.!Remove exposed abandoned conduit, including abandoned conduit above accessible ceiling
finishes. Cut conduit flush with walls and floors, and patch surfaces.
D.!Disconnect abandoned outlets and remove devices. Remove abandoned outlets if conduit
serving them is abandoned and removed. Provide blank cover for abandoned outlets which
are not removed.
E.!Disconnect and remove abandoned panelboards, distribution equipment and electrical
devices.
F.!Repair adjacent construction and finishes damaged during demolition and extension work.
G.!Maintain access to existing installations which remain active. Modify installation or provide
access to panels as appropriate.
H.!Where the demolition or revision of any portion of a raceway or box in the raceway system,
in an area, causes the raceway system of the area to no longer comply with the
classification or specification requirements of the area, the Contractor shall provide and
install such boxes, fittings, etc. as may be necessary to return the raceway system to
compliance with Specifications.
I.!Extend existing installations using materials and methods as specified for new work.
J.!Carry out the work in an orderly and careful manner. Hold noise, dust, and vibration to a
minimum, and conduct the Work so as to avoid any damage to the surroundings. Remove
all items and parts as shown and noted on the Drawings and as otherwise may be required
to be removed to carry out the Work.
K.!Salvaged Equipment and Materials
1.!The Owner shall have the right to retain any or all electrical and instrumentation
equipment shown or specified to be removed from the site.
2.!Prior to starting demolition, the Contractor and Owner/Engineer shall jointly visit the
areas of demolition and the Owner/Engineer will designate those items that are to
remain the property of the Owner.
3.!Equipment and material designated by the Owner, as remaining the property of the
Owner, shall be removed from the structure and hauled to a designated location on
surrounding grade and cover with weather resistant covering and tie securely or store
inside Owner furnished storage as directed by the Owner/Engineer.
4.!Take necessary precautions in removing Owner-designated property to prevent
damage during the demolition process. Remove steel structural members by
unbolting, cutting welds, or cutting rivet heads and punching shanks through holes.
Do not use a cutting torch t
approved by the Owner/Engineer.
5.!Generally, items to be salvaged shall be removed in one piece or in a manner that
does not impact their reuse. Loose components may be removed separately. Controls
and electrical equipment may be removed from the equipment and handled
separately. Large units may be handled separately. Salvaged piping shall be taken
apart at flanges or fittings and removed in sections.
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0537-038-01 SELECTIVE DEMOLITION FOR ELECTRICAL JANUARY 2023
L.!Material removed from the construction site during demolition, and any equipment not
otherwise designated to remain the property of the Owner in accordance with the pre-
demolition identification process, shall become the property of the Contractor, and shall be
promptly removed from the construction site.
M.!The Contractor shall refurbish and replace any existing facility to be left in place which is
damaged by the demolition operations at no additional expense to the Owner. The repair of
such damage shall leave the parts in a condition at least equal to that found at the start of
the Work.
3.3!CLEANING AND REPAIR
A.!Clean and repair existing materials and equipment which are to remain or are to be reused.
B.!Panelboards: Clean exposed surfaces and check tightness of electrical connections. Replace
damaged circuit breakers and provide closure plates for vacant positions. Provide typed
circuit directory showing revised circuiting arrangement. Materials and equipment for
patching and extending work: As specified in individual Sections.
END OF SECTION
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0537-038-01 SELECTIVE DEMOLITION FOR ELECTRICAL JANUARY 2023
SECTION 26 05 19
LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES
PART 1 - GENERAL
1.1!SUMMARY
A.!This Section includes the following:
1.!Building wires and cables rated 600 V and less.
2.!Connectors, splices, and terminations rated 600 V and less.
3.!Sleeves and sleeve seals for cables.
1.2!DEFINITIONS
A.!EPDM: Ethylene-propylene-diene terpolymer rubber.
B.!NBR: Acrylonitrile-butadiene rubber.
1.3!SUBMITTALS
A.!Product Data: For each type of product indicated.
1.4!QUALITY ASSURANCE
A.!Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70
Article 100 by a testing agency acceptable to authorities having jurisdiction and marked for
intended use.
B.!Comply with NFPA 70.
1.5!COORDINATION
A.!Set sleeves in cast-in-place concrete, masonry walls, and other structural components as
they are constructed.
PART 2 - PRODUCTS
2.1!CONDUCTORS AND CABLES
A.!Available Manufacturers: Subject to compliance with requirements, Manufacturers offering
products that may be incorporated into the work include, but are not limited to, the
following:
1.!Alcan Products Corporation; Alcan Cable Division.
2.!American Insulated Wire Corp.; a Leviton Company.
3.!General Cable Corporation.
4.!Houston Wire and Cable Company
5.!Senator Wire & Cable Company.
6.!Southwire Company.
7.!Okonite Company
8.!Rome Company
B.!Single Conductors:
1.!Unless otherwise indicated, all conductors shall be copper and shall be stranded. Solid
conductors shall be allowed on 120-V lighting and receptacle circuits.
2.!Utilize only conductors meeting applicable requirements of NEMA WC 3, WC 5, WC 7,
and ICEA S-19-81, S-61-402, and S-66-524.
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3.Insultation Requirements:
Conductor sizes No. 6 and larger provide conductors with type RHH or RHW.
Conductor sizes smaller than No. 6 provide conductors with XHHW.
For lighting and receptacles, provide conductors with THHN or THWN.
4.Unless noted otherwise, conductor sizes indicated are based on copper conductors.
Do not provide conductors smaller than those indicated.
5.Where flexible cords and cables are specified, provide Type SO, 600V with the
number andsize of copper conductors indicated.
C.Multi-Conductor Cable:
1.Provide cable that is UL listed Type TC and conforms to the requirements of UL1277
and NEC Article340, or UL listed Power Limited Circuit Cable that conforms to the
requirements of NECArticle725. Provide cables permanently and legibly marked with
the Manufacturer's name, the maximum working voltage for which the cable was
tested, the type of cable, and labeled UL (or submit evidence of UL listing).
2.600V Multi-Conductor Control Cable, Type TC:
General: Multi-conductor control circuit interconnection cable with ground.
Suitable for installation in open air, in cable trays, conduit, or other approved
raceways. Minimum cable temperature rating 90°C dry locations, 75°C wet
locations. Passes vertical tray flame test.
Individual Conductors: No.14 AWG, 7-strand copper.
Insulation and Jackets: Provide conductors insulated with flame retardant
ethylene propylene rubber, UL rated VW-1. Conductors identified by colors per
ICEAMethod1K2 (no greensand whites) and assembled to ICEA standards.
Outer jacket flame retardant, sunlight resistant and oil resistant,
chlorosulfonated polyethylene (CSPE) with nominal thickness per ICEA
standards.
3.600V Multi-Conductor Power Cable, Type TC:
General: Three-conductor or 4-conductor, with ground and overall jacket
suitable for installation in open air, cable trays, conduit, or other approved
raceways. Minimum cable temperature rating 90°C dry locations, 75°C wet
locations.
Individual Conductors: Class B stranded, coated, or uncoated copper.
Insulation and Jackets: Provide conductors insulated with flame retardant
ethylene propylene rubber, UL rated VW-1. Conductors identified by colors per
ICEA Method 1 K2 (no greens and whites) and assembled to ICEA standards.
Outer jacket flame retardant, sunlight resistant, and oil resistant,
chlorosulfonated polyethylene (CSPE) with nominal thickness per ICEA
standards.
4.Single Pair (600 V No.16 AWG Twisted, shielded Pair Instrumentation Cable, Type
TC):
General: Single pair instrumentation cable designed for noise rejection for
process control, computer, or data log applications. Suitable for installation in
cable trays, conduit, or other approved raceways. Minimum cable temperature
rating shall be 90°C dry locations, 75°C wet locations.
Individual Conductors: Soft annealed copper, Class B, 7-strand concentric per
ASTMB8, 20AWG, 7-strand copper drain wire.
Insulation and Jacket: Each conductor 15-mil nominal PVC and 4-mil nylon
insulation. Pair conductors pigmented blackand red. Jacket flame-retardant
and sunlight and oil resistant PVC with 45-mils nominal thickness. Shield
1.35mil aluminum, Mylar overlapped, to provide 100% coverage.
Dimension: 0.31inch nominal
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0537-038-01LOW-VOLTAGE POWER CONDUCTORS AND CABLESJANUARY 2023
5.Multi-pair (600V No.16 AWG, Multi-twisted Shielded Pairs with a Common Overall
Shield Instrumentation Cable, Type TC):
General: Twisted, shielded pairs of instrument cables, grouped in a single
cable with an overall shield, designed for use as instrumentation, process
control, and computer cable. Suitable for installation in cable tray, conduit, or
other approved raceways. Minimum cable temperature rating shall be 90°C dry
locations, 75°C wet locations.
Conductors: Soft annealed copper, Class B, 7-strand concentric per ASTMB8.
Copper drain wires. Pair drainwire size AWG20; group drain wire size AWG18.
Insulation and Jacket: Each conductor 25-mil flame retardant ethylene
propylene pigmented black and red with red conductor numerically printed for
group identification. Outer jacket flame retardant and sunlight and oil resistant
chlorinated polyethylene (CPE) with nominal thickness. Individual pair shield
1.35-mil aluminum-mylar with tin plated copper drain wire. Group shield 2.35-
mil aluminum-mylar, overlapped for 100% coverage.
D.Type P Four Conductor Power Cable
1.General: Four (4) insulated power conductors, armored and sheathed for demanding
environments of offshore drilling and petroleum facilities.
Individual Conductors: Soft annealed flexible stranded tinned copper per IEEE
1580 Table 11.
Insulation: Fame retardant cross-linked polyolefin, meeting the requirements
for Type P of IEEE 1580 and Type X110 of UL 1309/CSA C22.2 No. 245.
Jacket: Black, active grade, flame retardant, oil, abrasion, chemical and
sunlight resistant thermosetting compound meeting UL 1309/CXS C22.2 No.
245 and IEEE 1580.
Armor: Basket weave bronze wire armor per IEEE 1580 and UL 1309/CSA
C22.2 No. 245.
Sheath: Black, active grade, flame retardant, oil, abrasion, chemical and
sunlight resistant thermosetting compound meeting UL 1309/CXS C22.2 No.
245 and IEEE 1580.,
PART 3 -EXECUTION
3.1INSTALLATION OF CONDUCTORS AND CABLES
A.Do not exceed cable manufacturer's recommendations for maximum pulling tensions and
minimum bending radii. Pulling compound shall be used. Use only UL listed compound
compatible with the cable outer jacket and with the raceway involved.
B.Tighten screws and terminal bolts using torque type wrenches, and/or drives, to tighten to
the inch-pound requirements of the NEC and UL.
C.Where single conductors and cables in manholes, handholes, vaults, cable trays, and other
indicated locations are not wrapped together by some other means such as arc and
fireproofing tapes, bundle throughout their exposed length conductors entering from each
conduit with nylon, self-locking, releasable, cable ties placed at intervals not exceeding
12inches on centers.
3.2CONDUCTOR -600 V AND BELOW
A.Provide conductor sizes as indicated on the drawings.
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0537-038-01LOW-VOLTAGE POWER CONDUCTORS AND CABLESJANUARY 2023
B.!Wire nuts may be used on solid conductors of 120 V and 277 V lighting and 120 V
receptacle circuits only. Use King silicone filled pressure connectors or approved equal. Use
crimp connectors on all stranded conductors. Place no more than one conductor in any
single-barrel pressure connection.
C.!Soldered mechanical joints insulated with tape will not be acceptable.
D.!Vinyl plastic insulating tape for wire and cable splices and terminations shall be flame
retardant, 7-mil thick minimum, rated for 90ºC minimum meeting the requirements of
UL 510.
E.!Provide terminals and connectors acceptable for the type of material used.
F.!Arrange wiring in cabinets, panels, and motor control centers neatly cut to proper length.
Remove surplus wire, and bridle and secure in an acceptable manner. Identify circuits
entering motor control centers or other control cabinets in accordance with the conductor
identification system specified herein.
G.!Terminate control and instrumentation wiring with methods consistent with terminals
provided, and in accordance with terminal manufacturer's instructions. Where terminals
provided will accept such lugs, terminate control and instrumentation wiring (except solid
thermocouple leads) with insulated, locking-fork compression lugs, Thomas & Betts, Sta-
Kon, or equal.
H.!For terminals designed to accept only bare wire compression terminations, use only
stranded wire, and terminate only one wire per terminal. Tighten terminal screws with
torque screwdriver to recommended torque values.
I.!Attach compression lugs with a tool specifically designed for that purpose which provides a
complete, controlled, crimp where the tool will not release until the crimp is complete. Use
of plier type crimpers is not acceptable.
J.!Cap spare conductors and conductors not terminated with UL listed end caps.
K.!Where conductors pass through holes or over edges in sheet metal, remove all burrs,
chamfer edges, and install bushings and protective strips of insulating material to protect
the conductors.
L.!For conductors that will be connected by others, provide at least 6 feet spare conductor in
freestanding panels, and at least 2 feet spare in other assemblies. Provide additional spare
length in any particular assembly where it is obvious that more conductor length will be
needed to reach the termination point.
3.3!CABLES
A.!Do not splice without permission of the ENGINEER. Locate splices, when permitted, only in
readily accessible cabinets or junction boxes using terminal strips.
B.!Where connections of cables installed under this section are to be made to instrumentation
and controls, leave pigtails of adequate length for neat bundled type connections.
C.!Maintaining the integrity of shielding of instrumentation cables is essential to the operation
of the control systems. Take special care in cable installation to ensure that grounds do not
occur because of damage to the jacket over the shield.
3.4!CABLE PLACEMENT:
A.!Immediately prior to the placement of each cable or cable group, inspect the raceway to
determine that installation is complete and that the interior is clean and free of all materials
detrimental to the cable or its placement. Group all cable assigned to a particular conduit
and pulled simultaneously, using cable grips and acceptable lubricants.
B.!Provide adequately sized raceways to accommodate the number and size of cable as
specified, and in compliance with Article 300 of the National Electric Code. If at any time
during the progress of the work raceways appear inadequate to accommodate the assigned
cable, notify the Owner at once and discontinue further work on the questionable raceway
until advised by the Owner as to how to proceed.
PLUMMER ASSOCIATES, INC. 26 05 19 - PAGE 4 OF 6 BID SET
0537-038-01 LOW-VOLTAGE POWER CONDUCTORS AND CABLES JANUARY 2023
C.Carefully check all cable as to size and length before pulling into conduits. Remove and
replace cable pulled into the wrong conduit or cut too short at no additional cost to the
Owner. Do not pull cable removed from one conduit or duct into another conduit or duct
without permission of the Owner.
D.Fishing and pulling shall be performed with flexible round non-metallic tape, carbon dioxide,
or forced air propelled polyethylene cord, nylon rope, or manila rope. No metallic cable or
materials that may damage or scratch the inside surface shall be pulled into any conduit.
E.Use woven wire cable grips to pull all low voltage single conductor cable, No.2/0 and larger,
and all low voltage multi-conductor cable. Use pulling loops to pull single conductor cable
smaller than No. 2/0. When a cable grip is used for pulling, the arc of the cable covered by
the grip plus 6inches shall be cut off and discarded.
F.Insert a reliable non-freezing type of swivel or swivel connection between the pulling ropes
and the cable eye, or grip to prevent twisting under strain.
G.Do not exceed the maximum pulling tension recommended by the cable manufacturer.
Pulling mechanisms of both the manual and power types shall have the rated capacity in
tons clearly marked on the mechanism. Whenever the capacity of the pulling mechanism
exceeds the recommended pulling tension of the cable as given by the cable manufacturer,
a dynamometer shall be used to show the tension on the cable, and the indicator shall be
constantly watched. If any excessive strain develops, stop the pulling operation at once and
determine and correct the difficulty.
3.5CONDUCTOR ARC AND FIREPROOFING TAPES
A.Use arc and fireproofing tapes on 600V single conductors and cables, except those rated
Type TC, throughout their entire exposed length at splices in manholes, handholes, vaults,
cable trays, and other indicated locations.
B.Wrap together as a single cable conductors entering from each conduit.
C.Follow tape manufacturer's installation instructions. Secure the arc and fireproofing tape at
frequent intervals with bands of the specified glass cloth electrical tape. Make each band of
at least two wraps of tape directly over each other.
3.6FIELD QUALITY CONTROL
A.Perform tests and inspections and prepare test reports.
B.Tests and Inspections:
1.After installing conductors and cables and before electrical circuitry has been
energized, testservice entrance and feeder conductors, and conductors feeding the
following critical equipment and services for compliance with requirements.
2.Perform each visual and mechanical inspection and electrical test stated in NETA
Acceptance Testing Specification. Certify compliance with test parameters.
3.Infrared Scanning: After Substantial Completion, but not more than 60days after
Final Acceptance, perform an infrared scan of eachsplice in cables and conductors
No.3AWG and larger. Remove box and equipment covers so splices are accessible to
portable scanner.
Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of
each splice 11months after date of Substantial Completion.
Instrument: Use an infrared scanning device designed to measure temperature
or to detect significant deviations from normal values. Provide calibration
record for device.
Record of Infrared Scanning: Prepare a certified report that identifies splices
checked and that describes scanning results. Include notation of deficiencies
detected, remedial action taken, and observations after remedial action.
C.Test Reports: Prepare a written report to record the following:
PLUMMER ASSOCIATES, INC.26 05 19-PAGE 5OF 6BID SET
0537-038-01LOW-VOLTAGE POWER CONDUCTORS AND CABLESJANUARY 2023
1.!Test procedures used.
2.!Test results that comply with requirements.
3.!Test results that do not comply with requirements and corrective action taken to
achieve compliance with requirements.
D.!Remove and replace malfunctioning units and retest as specified above.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 05 19 - PAGE 6 OF 6 BID SET
0537-038-01 LOW-VOLTAGE POWER CONDUCTORS AND CABLES JANUARY 2023
SECTION 26 05 26
GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1!RELATED DOCUMENTS
A.!Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
1.2!SUMMARY
A.!This Section includes methods and materials for grounding systems and equipment, plus the
following special applications:
1.!Underground distribution grounding.
2.!Common ground bonding with lightning protection system.
1.3!SUBMITTALS
A.!Product Data: For each type of product indicated.
B.!Other Informational Submittals: Plans showing dimensioned as-built locations of grounding
features specified in Part 3 "Field Quality Control" Article, including the following:
1.!Test wells.
2.!Ground rods.
3.!Ground rings.
4.!Grounding arrangements and connections for separately derived systems.
5.!Grounding for sensitive electronic equipment.
C.!Field quality-control test reports.
D.!Operation and Maintenance Data: For grounding to include the following in emergency,
operation, and maintenance manuals:
1.!Instructions for periodic testing and inspection of grounding features at test wells
ground rings grounding connections for separately derived systems based on
NFPA 70B.
a.!Tests shall be to determine if ground resistance or impedance values remain
within specified maximums, and instructions shall recommend corrective action
if they do not.
b.!Include recommended testing intervals.
1.4!QUALITY ASSURANCE
A.!Electrical Components, Devices, and Accessories: Listed and labeled as defined in
NFPA 70 Article 100 by a testing agency acceptable to authorities having jurisdiction and
marked for intended use.
B.!Comply with UL 467 for grounding and bonding materials and equipment.
PART 2 - PRODUCTS
2.1!CONDUCTORS
A.!Insulated Conductors: Tinned-copper wire or cable insulated for 600 V unless otherwise
required by applicable Code or authorities having jurisdiction.
B.!Bare Copper Conductors:
1.!Solid Conductors: ASTM B 3.
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0537-038-01 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS JANUARY 2023
2.!Stranded Conductors: ASTM B 8.
3.!Tinned Conductors: ASTM B 33.
4.!Bonding Cable: 28 kcmil, 14 strands of No. 17 AWG conductor, 1/4 inches in
diameter.
5.!Bonding Conductor: No. 4 or No. 6 AWG, stranded conductor.
6.!Bonding Jumper: Copper tape, braided conductors, terminated with copper ferrules;
1-5/8 inches wide and 1/16 inches thick.
7.!Tinned Bonding Jumper: Tinned-copper tape, braided conductors, terminated with
copper ferrules; 1-5/8 inches wide and 1/16 inches thick.
C.!Grounding Bus: Rectangular bars of annealed copper, 1/4x2 inches in cross section, unless
otherwise indicated; with insulators.
2.2!CONNECTORS
A.!Listed and labeled by a nationally recognized testing laboratory acceptable to authorities
having jurisdiction for applications in which used, and for specific types, sizes, and
combinations of conductors and other items connected.
B.!Bolted Connectors for Conductors and Pipes: Copper or copper alloy, bolted pressure-type,
with at least two bolts.
1.!Pipe Connectors: Clamp type, sized for pipe.
C.!Welded Connectors: Exothermic-welding kits of types recommended by kit MANUFACTURER
for materials being joined and installation conditions.
2.3!GROUNDING ELECTRODES
A.!Ground Rods: Copper-clad steel; 3/4 inch by 10 feet in diameter.
PART 3 - EXECUTION
3.1!APPLICATIONS
A.!Conductors: Install solid conductor for No. 8 AWG and smaller, and stranded conductors for
No. 6 AWG and larger, unless otherwise indicated.
B.!Underground Grounding Conductors: Install bare tinned-copper conductor, No. 4/0 AWG
minimum.
1.!Bury at least 24 inches below grade.
2.!Duct-Bank Grounding Conductor: Bury 12 inches above duct bank when indicated as
part of duct-bank installation.
C.!Isolated Grounding Conductors: Green-colored insulation with continuous yellow stripe. On
feeders with isolated ground, identify grounding conductor where visible to normal
inspection, with alternating bands of green and yellow tape, with at least three bands of
green and two bands of yellow.
D.!Grounding Bus: Install in electrical and telephone equipment rooms, in rooms housing
service equipment, and elsewhere as indicated.
1.!Install bus on insulated spacers 1 inch, minimum, from wall 6 inches above finished
floor, unless otherwise indicated.
2.!Where indicated on both sides of doorways, route bus up to top of door frame, across
top of doorway, down to specified height above floor, and connect to horizontal bus.
E.!Conductor Terminations and Connections:
1.!Pipe and Equipment Grounding Conductor Terminations: Bolted connectors.
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0537-038-01 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS JANUARY 2023
2.!Underground Connections: Welded connectors except at test wells and as otherwise
indicated.
3.!Connections to Ground Rods at Test Wells: Bolted connectors.
4.!Connections to Structural Steel: Welded connectors.
3.2!GROUNDING UNDERGROUND DISTRIBUTION SYSTEM COMPONENTS
A.!Comply with IEEE C2 grounding requirements.
B.!Grounding Manholes and Handholes: Install a driven ground rod through manhole or
handhole floor, close to wall, and set rod depth so 4 inches will extend above finished floor.
If necessary, install ground rod before manhole is placed and provide No. 4/0 AWG bare,
tinned-copper conductor from ground rod into manhole through a waterproof sleeve in
manhole wall. Protect ground rods passing through concrete floor with a double wrapping of
pressure-sensitive insulating tape or heat-shrunk insulating sleeve from 2 inches above to
6 inches below concrete. Seal floor opening with waterproof, nonshrink grout.
C.!Grounding Connections to Manhole Components: Bond exposed-metal parts such as inserts,
cable racks, pulling irons, ladders, and cable shields within each manhole or handhole, to
ground rod or grounding conductor. Make connections with No. 4 AWG minimum, stranded,
hard-drawn copper bonding cond
fasten to manhole walls. Connect to cable armor and cable shields as recommended by
manufacturer of splicing and termination kits.
D.!Pad-Mounted Transformers and Switches: Install two ground rods and ground ring around
the pad. Ground pad-mounted equipment and noncurrent-carrying metal items associated
with substations by connecting them to underground cable and grounding electrodes. Install
tinned-copper conductor not less than No. 4/0 AWG for ground ring and for taps to
equipment grounding terminals. Bury ground ring not less than 6 inches from the
foundation.
3.3!EQUIPMENT GROUNDING
A.!Install insulated equipment grounding conductors with all feeders and branch circuits.
B.!Install insulated equipment grounding conductors with the following items, in addition to
those required by NFPA 70:
1.!Feeders and branch circuits.
2.!Lighting circuits.
3.!Receptacle circuits.
4.!Single-phase motor and appliance branch circuits.
5.!Three-phase motor and appliance branch circuits.
6.!Flexible raceway runs.
7.!Armored and metal-clad cable runs.
8.!Busway Supply Circuits: Install insulated equipment grounding conductor from
grounding bus in the switchgear, switchboard, or distribution panel to equipment
grounding bar terminal on busway.
9.!Computer and Rack-Mounted Electronic Equipment Circuits: Install insulated
equipment grounding conductor in branch-circuit runs from equipment-area power
panels and power-distribution units.
C.!Water Heater, Heat-Tracing, and Antifrost Heating Cables: Install a separate insulated
equipment grounding conductor to each electric water heater and heat-tracing cable. Bond
conductor to heater units, piping, connected equipment, and components.
D.!Isolated Grounding Receptacle Circuits: Install an insulated equipment grounding conductor
connected to the receptacle grounding terminal. Isolate conductor from raceway and from
panelboard grounding terminals. Terminate at equipment grounding conductor terminal of
the applicable derived system or service, unless otherwise indicated.
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0537-038-01 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS JANUARY 2023
E.!Isolated Equipment Enclosure Circuits: For designated equipment supplied by a branch
circuit or feeder, isolate equipment enclosure from supply circuit raceway with a nonmetallic
raceway fitting listed for the purpose. Install fitting where raceway enters enclosure and
install a separate insulated equipment grounding conductor. Isolate conductor from raceway
and from panelboard grounding terminals. Terminate at equipment grounding conductor
terminal of the applicable derived system or service, unless otherwise indicated.
F.!Signal and Communication Equipment: For telephone, alarm, voice and data, and other
communication equipment, provide No. 4 AWG minimum insulated grounding conductor in
raceway from grounding electrode system to each service location, terminal cabinet, wiring
closet, and central equipment location.
1.!Service and Central Equipment Locations and Wiring Closets: Terminate grounding
conductor on a 1/4x2x12-inch grounding bus.
2.!Terminal Cabinets: Terminate grounding conductor on cabinet grounding terminal.
G.!Metal Poles Supporting Outdoor Lighting Fixtures: Install grounding electrode and a
separate insulated equipment grounding conductor in addition to grounding conductor
installed with branch-circuit conductors.
3.4!INSTALLATION
A.!Grounding Conductors: Route along shortest and straightest paths possible, unless
otherwise indicated or required by Code. Avoid obstructing access or placing conductors
where they may be subjected to strain, impact, or damage.
B.!Common Ground Bonding with Lightning Protection System: Comply with NFPA 780 and
UL 96 when interconnecting with lightning protection system. Bond electrical power system
ground directly to lightning protection system grounding conductor at closest point to
electrical service grounding electrode. Use bonding conductor sized same as system
grounding electrode conductor, and install in conduit.
C.!Ground Rods: Drive rods until tops are 2 inches below finished floor or final grade, unless
otherwise indicated.
1.!Interconnect ground rods with grounding electrode conductor below grade and as
otherwise indicated. Make connections without exposing steel or damaging coating, if
any.
D.!Test Wells: Ground rod driven through drilled hole in bottom of handhole. Handholes and
shall be at least 12 inches deep, with cover.
1.!Test Wells: Install at least one test well for each service, unless otherwise indicated.
Install at the ground rod electrically closest to service entrance. Set top of test well
flush with finished grade or floor.
E.!Bonding Straps and Jumpers: Install in locations accessible for inspection and maintenance,
except where routed through short lengths of conduit.
1.!Bonding to Structure: Bond straps directly to basic structure, taking care not to
penetrate any adjacent parts.
2.!Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports: Install
so vibration is not transmitted to rigidly mounted equipment.
3.!Use exothermic-welded connectors for outdoor locations, but if a disconnect-type
connection is required, use a bolted clamp.
F.!Grounding and Bonding for Piping:
1.!Metal Water Service Pipe: Install insulated copper grounding conductors, in conduit,
from building's main service equipment, or grounding bus, to main metal water
service entrances to building. Connect grounding conductors to main metal water
service pipes, using a bolted clamp connector or by bolting a lug-type connector to a
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0537-038-01 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS JANUARY 2023
pipe flange, using one of the lug bolts of the flange. Where a dielectric main water
fitting is installed, connect grounding conductor on street side of fitting. Bond metal
grounding conductor conduit or sleeve to conductor at each end.
2.!Water Meter Piping: Use braided-type bonding jumpers to electrically bypass water
meters. Connect to pipe with a bolted connector.
3.!Bond each aboveground portion of gas piping system downstream from equipment
shutoff valve.
G.!Bonding Interior Metal Ducts: Bond metal air ducts to equipment grounding conductors of
associated fans, blowers, electric heaters, and air cleaners. Install tinned bonding jumper to
bond across flexible duct connections to achieve continuity.
H.!Grounding for Steel Building Structure: Install a driven ground rod at base of each corner
column and at intermediate exterior columns at distances not more than 60 feet apart.
I.!Ground Ring: Install a grounding conductor, electrically connected to each building
structure ground rod and to each indicated item, extending around the perimeter of area or
item indicated.
1.!Install tinned-copper conductor not less than No. 4/0 AWG for ground ring and for
taps to building steel.
2.!Bury ground ring not less than 24 inches from building foundation.
3.5!FIELD QUALITY CONTROL
A.!Perform the following tests and inspections and prepare test reports:
1.!After installing grounding system but before permanent electrical circuits have been
energized, test for compliance with requirements.
2.!Test completed grounding system at each location where a maximum ground-
resistance level is specified, at service disconnect enclosure grounding terminal, at
ground test wells. Make tests at ground rods before any conductors are connected.
a.!Measure ground resistance not less than two full days after last trace of
precipitation and without soil being moistened by any means other than natural
drainage or seepage and without chemical treatment or other artificial means
of reducing natural ground resistance.
b.!Perform tests by fall-of-potential method according to IEEE 81.
3.!Prepare dimensioned drawings locating each test well, ground rod and ground rod
assembly, and other grounding electrodes. Identify each by letter in alphabetical
order, and key to the record of tests and observations. Include the number of rods
driven, their depth at each location, and include observations of weather and other
phenomena that may affect test results. Describe measures taken to improve test
results.
B.!Report measured ground resistances that exceed the following values:
1.!Power and Lighting Equipment or System with Capacity 500 kVA and Less: 10
2.!Power and Lighting Equipment or System with Capacity 500-1,000 kVA: 5
3.!Power and Lighting Equipment or System with Capacity More Than 1,000 kVA: 3
4.!Power Distribution Units or Panelboards Serving Electronic Equipment: 5
5.!Substations and Pad-Mounted Equipment: 5
6.!Manhole Grounds: 10
C.!Excessive Ground Resistance: If resistance to ground exceeds specified values, notify
Architect promptly and include recommendations to reduce ground resistance.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 05 26 - PAGE 5 OF 5 BID SET
0537-038-01 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS JANUARY 2023
SECTION 26 05 29
HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1!SUMMARY
A.!This Section includes the following:
1.!Hangers and supports for electrical equipment and systems.
2.!Construction requirements for concrete bases.
1.2!PERFORMANCE REQUIREMENTS
A.!Delegated Design: Design supports for multiple raceways, including comprehensive
engineering analysis by a qualified professional engineer, using performance requirements
and design criteria indicated.
B.!Design supports for multiple raceways capable of supporting combined weight of supported
systems and its contents.
C.!Design equipment supports capable of supporting combined operating weight of supported
equipment and connected systems and components.
D.!Rated Strength: Adequate in tension, shear, and pullout force to resist maximum loads
calculated or imposed for this Project, with a minimum structural safety factor of five times
the applied force.
1.3!SUBMITTALS
A.!Product Data: For the following:
1.!Steel slotted support systems.
2.!Anchor Bolts and Fasteners.
1.4!QUALITY ASSURANCE
A.!Comply with NFPA 70.
B.!Comply with MFMA-3.
1.5!DELIVERY, STORAGE, AND HANDLING
A.!Deliver strut systems and components carefully to avoid breakage, denting, and scoring
finishes. Do not install damaged equipment.
B.!Store strut systems and components in original cartons and in clean dry space. Protect from
weather and construction traffic.
PART 2 - PRODUCTS
2.1!SUPPORT, ANCHORAGE, AND ATTACHMENT COMPONENTS
A.!General: Strut shall be 1-5/8 inches wide in varying heights and welded combinations as
required to meet load capacities and designs indicated on the drawings.
B.!Materials and Finish: Material and finish specifications for each strut type are as follows:
1.!Aluminum: Strut shall be manufactured of extruded aluminum alloy 6063-T6. All
fittings and hardware shall be zinc plated according to ASTM B633 (SC3 for fittings,
SC1 for threaded hardware) for indoor use only. For outdoor use, all fittings and
hardware shall be stainless steel Type 304.
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0537-038-01 HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS JANUARY 2023
2.Stainless Steel: All fittings and hardware shall be made of AISIType316 stainless
steel.
3.Manufacturers: Subject to compliance with requirements, provide products by one of
the following:
Allied Tube & Conduit.
Cooper B-Line, Inc.; a division of Cooper Industries.
ERICO International Corporation.
GS MetalsCorp.
Thomas & Betts Corporation.
Unistrut; Tyco International, Ltd.
Wesanco, Inc.
C.Raceway and Cable Supports: As described in NECA1 and NECA101.
D.Conduit and Cable Support Devices: AISIType316 stainless steel hangers, clamps, and
associated fittings, designed for types and sizes of raceway or cable to be supported.
E.Support for Conductors in Vertical Conduit: Factory-fabricated assembly consisting of
threaded body and insulating wedging plug or plugs for non-armored electrical conductors
or cables inriser conduits. Plugs shall have number, size, and shape of conductor gripping
pieces as required to suit individual conductors or cables supported. Body shall be malleable
iron.
F.Structural Steel for Fabricated Supports and Restraints: ASTMA36/A36M, steel plates,
shapes, and bars. Black and galvanized.
G.Mounting, Anchoring, and Attachment Components: Items for fastening electrical items or
their supports to building surfaces include the following:
1.Mechanical-Expansion Anchors: Insert-wedge-type, stainless steel, for use in
hardened Portland cement concrete with tension, shear, and pullout capacities
appropriate for supported loads and building materials in which used.
Manufacturers: Subject to compliance with requirements, provide products by
one of the following:
Cooper B-Line, Inc.; a division of Cooper Industries.
Empire Tool and Manufacturing Co., Inc.
Hilti Inc.
ITW Ramset/Red Head; a division of Illinois Tool Works, Inc.
MKT Fastening, LLC.
2.Concrete Inserts: Stainless Steel, slotted support system units similar to
MSSType18; complying with MFMA-4 or MSSSP-58.
3.Clamps for Attachment to Steel Structural Elements: MSSSP-58, type suitable for
attached structural element.
4.Through Bolts: Structural type, hex head, and high strength. Comply with
ASTMA325.
5.Toggle Bolts: Stainless steel springhead type.
6.Hanger Rods: Threaded stainless steel.
2.2ANCHOR BOLTS AND ANCHOR BOLT SLEEVES
A.Cast-In-Place Anchor Bolts:
1.Unless otherwise shown on Drawings. F 593, AISI Type 316, Condition CW
B.Anchor Bolt Sleeves:
1.Plastic:
Single unit construction with corrugated sleeve.
Top of sleeve shall be self-threading to provide adjustment of threaded anchor
bolt projection.
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Material: High density polyethylene.
2.Fabricated Steel: ASTM A 36.
2.3CONCRETE AND MASONRY DRILLED ANCHORS
A.Mechanical Expansion Anchors:
1.Design Requirements: Anchor bolt and sleeve assembly shall have capability to
sustain without failure, as determined by the Strength Design method when installed
in cracked and uncracked concrete, in accordance with the International Building
Code and as determined by testing in accordance with ASTM E 488 and AC-355.2.
2.Material: AISI Type 304 and Type 316 stainless steel.
3.Current evaluation and acceptance reports by ICC or other similar code organization
and listed by UL and FM Global.
4.Acceptable for use in potable water structures by NSF and local health organizations.
5.Type:
ICC-ES Code Listed, Category 1, Cracked and Uncracked Concrete.
Self-drilling Anchors; snap-off or flush type, zinc-plated.
Non-drilling Anchors; flush type for use with zinc-plated or stainless-steel bolt,
or stud type with projecting threaded stud.
6.Size: As shown on Drawings and required for the concrete strength specified.
7.Manufacturers. Subject to compliance with requirements, available products that may
be incorporated into the Work include, but are not limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Fasteners, New Rochelle, NY
Simpson Strong-Tie Co., Inc., Pleasanton, CA
B.Wedge Bolts:
1.Material: Zinc plated, case hardened carbon steel.
2.Current evaluation and acceptance reports by ICC or other similar code organization
and listed by UL and FM Global.
3.Type:
ICC-ES Code Listed, Category 1, Cracked and Uncracked Concrete.
Description: One-piece, heavy duty screw anchor with finished hex head
suitable for cracked and uncracked concrete and grouted masonry.
4.Size: As shown on Drawings and required for the concrete strength specified.
5.Manufacturers. Subject to compliance with requirements, available products that may
be incorporated into the Work include, but are not limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Fasteners, New Rochelle, NY
Simpson Strong-Tie Co., Inc., Pleasanton, CA
C.Snake Anchors:
1.Material: Zinc plated, case hardened carbon steel.
2.Current evaluation and acceptance reports by ICC or other similar code organization
and listed by UL and FM Global.
3.Type:
ICC-ES Code Listed, Category 1, Cracked and Uncracked Concrete.
Description: Internally threaded, self-tapping screw anchor designed for
performance in cracked and uncracked concrete and grouted masonry. Suitable
base materials included normal-weight concrete, structural lightweight
concrete, and concrete over metal deck.
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4.Size: As shown on Drawings and required for the concrete strength specified.
5.Manufacturers. Subject to compliance with requirements, available products that may
be incorporated into the Work include, but are not limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Fasteners, New Rochelle, NY
6.Simpson Strong-Tie Co., Inc., Pleasanton, CA
D.Adhesive Anchors:
1.General: Adhesive anchoring system designed for bonding threaded anchor rod and
reinforcing bar hardware into drilled holes in concrete and solid masonry base
materials.
2.Threaded rod:
Material: Unless otherwise specified:
ASTM F 593 Stainless steel threaded rod, unless otherwise specified.
Diameter as shown on the Drawings or as required for the loads and
conditions.
Length as required to provide minimum depth of embedment.
Clean and free of grease, oil, or other deleterious material.
For hollow-unit masonry, provide galvanized or stainless-steel wire cloth screen
tube to fit threaded rod.
Anchor rods shall have rolled threads.
3.Adhesive:
Two-component, high strength adhesive anchoring system designed to be used
in adverse/thaw environments, with gray color mixing.
ICC-ES Code Listed.
Cure Temperature, Pot Life, and Workability: Compatible for the intended
use and environmental conditions.
Non-sag, with selected viscosity base on installation temperature and
overhead application where applicable.
ASTM Compliance:
Uncracked Concrete: Meets ASTM C881, Types I, II, IV, and V,
Grade 3, Class A and B.
Uncracked and Cracked Concrete: Meets ASTM C881, Types I, II,
IV, and V, Grade 3, Class B and C.
Compliant with NSF/ANSI Standard 61 for potable water applications.
Manufacturers: Subject to compliance with requirements, available
products that may be incorporated into the Work include, but are not
limited to, the following:
ITW Ramset/Red Head, Wood Dale, IL.
Hilti, Inc., Tulsa, OK
Powers Fasteners, New Rochelle, NY
Simpson Strong-Tie Co., Inc., Pleasanton, CA
E.Concrete Inserts:
1.For piping, grating andfloor plate provide malleable iron inserts.
2.Provide those recommended by the manufacturer for the required loading.
3.Finish shall be black.
F.Powder actuated fasteners and other types of bolts and fasteners not specified herein shall
not be used unless approved by ENGINEER.
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2.4!FABRICATED METAL EQUIPMENT SUPPORT ASSEMBLIES
A.!Description: Welded or bolted, structural-steel shapes, shop or field fabricated to fit
dimensions of supported equipment.
PART 3 - EXECUTION
3.1!APPLICATION
A.!Use stainless steel components unless otherwise shown on drawings.
B.!Comply with NECA 1 and NECA 101 for application of hangers and supports for electrical
equipment and systems except if requirements in this Section are stricter.
C.!Maximum Support Spacing and Minimum Hanger Rod Size for Raceway: Space supports for
conduit and cable tray as scheduled in NECA 1, where Table 1 lists maximum spacing less
than stated in NFPA 70. Minimum rod size shall be 1/4 inch in diameter.
D.!Multiple Raceways or Cables: Install trapeze-type supports fabricated with support system,
sized so capacity can be increased by at least 25% in the future without exceeding specified
design load limits.
1.!Secure raceways and cables to these supports with single-bolt conduit clamps.
E.!Spring-steel clamps designed for supporting single conduits without bolts may be used for 1-
1/2 inch and smaller raceways serving branch circuits and communication systems above
suspended ceilings and for fastening raceways to trapeze supports.
3.2!SUPPORT INSTALLATION
A.!Comply with NECA 1 and NECA 101 for installation requirements except as specified in this
Article.
B.!Raceway Support Methods: In addition to methods described in NECA 1, conduit may be
supported by openings through structure members, as permitted in NFPA 70.
C.!Strength of Support Assemblies: Where not indicated, select sizes of components so
strength will be adequate to carry present and future static loads within specified loading
limits. Minimum static design load used for strength determination shall be the weight of
supported components plus 200 lb.
D.!Mounting and Anchorage of Surface-Mounted Equipment and Components: Anchor and
fasten electrical items and their supports to building structural elements by the following
methods unless otherwise indicated by code:
1.!To Wood: Fasten with lag screws or through bolts.
2.!To New Concrete: Bolt to concrete inserts.
3.!To Masonry: Approved toggle-type bolts on hollow masonry units and expansion
anchor fasteners on solid masonry units.
4.!To Existing Concrete: Expansion anchor fasteners.
5.!To Steel: Beam clamps (MSS Type 19, 21, 23, 25, or 27) complying with MSS SP-69.
6.!To Light Steel: Sheet metal screws.
7.!Items Mounted on Hollow Walls and Nonstructural Building Surfaces: Mount cabinets,
panelboards, disconnect switches, control enclosures, pull and junction boxes,
transformers, and other devices on slotted-channel racks attached to substrate.
E.!Drill holes for expansion anchors in concrete at locations and to depths that avoid
reinforcing bars.
3.3!INSTALLATION OF FABRICATED METAL SUPPORTS
A.!Cut, fit, and place miscellaneous metal supports accurately in location, alignment, and
elevation to support and anchor electrical materials and equipment.
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B.Field Welding: Comply with AWSD1.1/D1.1M.
3.4CONCRETE BASES
A.Construct concrete bases of dimensions indicated but not less than 4inches larger in both
directions than supported unit, and so anchors will be a minimum of 10bolt diameters from
edge of the base.
B.Materials
1.Cementitious Material: Use the following cementitious materials, of the same type,
brand, and source throughout Project:
2.Portland Cement: ASTMC150, TypeII or Type 1/II.Supplement with the following:
Fly Ash: ASTMC618, ClassC. Fly ash may be used for replacement of up to
15% of cement content by weight except for paving concrete.
3.Normal-Weight Aggregate: ASTMC33, graded, 1inch nominal maximum aggregate
size.
4.Water: ASTMC94;potable.
C.Concrete Mixtures
1.Comply with ACI301 requirements for concrete mixtures.
2.Provide concrete with the following mix design to result in concrete placed in the field
of minimum compressive strength of 3,000psi at 28 days based on test cylinders
which are taken during concrete placement.
UnitMeasurement
Minimum Compressive Strength (7 day)2,250 psi
Minimum Compressive Strength (28 day)3,000 psi
Coarse AggregateASTMC33, No. 467
Fine AggregateASTMC33
Water/Cementious Ratio (max.)0.50 by weight
Air Entrainment4-6 percent
Slump with Superplasticizer7inches to 9inches
Slump without Superplasticizer3inches 1inch
Minimum Cementious Content470pounds per cubic yard
D.Additive
1.Red ferrous oxide concrete coloring pigment mixed at the rate of 1-1/2lb. per sack
of cement for electrical conduit.
E.Anchor equipment to concrete base.
1.Place and secure anchorage devices.Use supported equipment manufacturer's setting
drawings, templates, diagrams, instructions, and directions furnished with items to be
embedded.
2.Install anchor bolts to elevations required for proper attachment to supported
equipment.
3.Install anchor bolts according to anchor-bolt manufacturer's written instructions.
3.5PAINTING
A.Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply
galvanizing-repair paint to comply with ASTMA780.
END OF SECTION
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SECTION 26 05 33
RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1!SUMMARY
A.!This Section includes raceways, fittings, boxes, enclosures, and cabinets for electrical wiring.
1.2!SUBMITTALS
A.!Product Data: For surface raceways, wireways and fittings, floor boxes, hinged-cover
enclosures, and cabinets.
B.!Shop Drawings: For the following raceway components. Include plans, elevations, sections,
details, and attachments to other work.
1.3!QUALITY ASSURANCE
A.!Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70
Article 100 by a testing agency acceptable to authorities having jurisdiction and marked for
intended use.
B.!Comply with NFPA 70.
PART 2 - PRODUCTS
2.1!ALUMINUM CONDUIT AND FITTINGS
A.!Available Manufacturers: Subject to compliance with requirements, manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.!Allied Tube & Conduit; a Tyco International Ltd. Co.
2.!American Conduit, by SAPA
3.!Republic Conduit
B.!Aluminum Rigid Conduit:
1.!Alloy: Manufactured of 6063 alloy in temper designation T-1.
2.!Standards: UL 6A, "Standard for Electrical Rigid Metal Conduit - Aluminum, Red Brass
and Stainless Steel" and is manufactured to ANSI C80.5.
C.!Fittings for Conduit (Including all Types and Flexible and Liquidtight), and Cable:
NEMA FB 1; listed for type and size raceway with which used, and for application and
environment in which installed.
1.!Conduit Fittings for Hazardous (Classified) Locations: Comply with UL 886.
2.2!PVC COATED ALUMINUM CONDUIT AND FITTINGS
A.!Available Manufacturers: Subject to compliance with requirements, manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.!American Conduit, by SAPA
2.!OCAL, Inc.
3.!Perma-Cote
B.!PVC-Coated Aluminum Rigid Conduit:
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1.Alloy: Manufactured of 6063 alloy in temper designation T-1.
2.Standards: UL6A, "Standard for Electrical Rigid Metal Conduit -Aluminum, Red Brass
and Stainless Steel" and is manufactured to ANSIC80.5.
3.Coating Thickness: 0.040inch, minimum.
C.Fittings for Conduit (Including all Types and Flexible and Liquidtight), and Cable:
NEMAFB1; listed for type and size raceway with which used, and for application and
environment in which installed.
1.Coating forFittings for PVC-Coated Conduit: Minimum thickness of 0.040inch with
overlapping sleeves protecting threaded joints.
2.3BOXES, ENCLOSURES, AND CABINETS
A.Available Manufacturers: Subject to compliance with requirements, manufacturersoffering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.Cooper Crouse-Hinds; Div. of Cooper Industries, Inc.
2.EGS/Appleton Electric.
3.Hoffman.
4.Hubbell Incorporated; Killark Electric Manufacturing Co. Division.
5.Perma-Cote
B.Cast-Metal Outlet and Device Boxes: NEMAFB1, aluminum, TypeFD, with gasketed cover.
C.Metal Floor Boxes: Cast metal, fully adjustable, rectangular.
D.Small Sheet Metal Pull and Junction Boxes: NEMAOS1.
E.Cast-Metal Access, Pull, and Junction Boxes: NEMAFB1, cast aluminum with gasketed
cover.
F.Hinged-Cover Enclosures: NEMA250, Type4X, with continuous-hinge cover with fast-
operating clamp-cover junction box clamp, Type316 stainless steel, unless otherwise
indicated.
1.Metal Enclosures: Stainless Steel Type316.
2.4TERMINATION CABINETS & BOXES
A.Termination cabinets shall be NEMA4X, Type316 stainless steel gasketed. Cabinets shall be
configured as shown on the plans, and shall be of sufficient size to adequately contain all
terminals, wire-duct, and cables as determined by the CONTRACTOR. Cabinets shall have
fast-operating clamp-cover junction box clamp, Type316 stainless steel.
B.Acceptable manufacturers: Hoffman.
2.5WIREWAY
A.General:
1.Suitable for lay-in conductors.
2.Designed for continuous grounding.
3.Covers:
Hinged or removable in accessible areas.
Non-removable when passing through partitions.
4.Finish: Rust inhibiting primer and manufacturer's standard paint inside and out except
for stainless steel type.
5.Standards: UL870, NEMA250.
B.Watertight (NEMA4X rated) Wireway:
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1.14Gauge Type 304 or 316 stainless steel bodies and covers without knockouts and
10Gauge stainless steel flanges.
2.Cover: Fully gasketed and held in place with captive clamp type latches.
3.Flanges: Fully gasketed and bolted.
2.6CONDUIT BODIES AND FITTINGS AND ACCESSORIES
A.Fittings for Use with Aluminum Conduit:
1.General:
In hazardous locations listed for use in ClassI, GroupsC and D locations.
2.Locknuts:
Threaded stainless steel.
Gasketed or non-gasketed.
Grounding or non-grounding type.
3.Bushings:
Threaded, insulated metallic.
Grounding or non-grounding type.
4.Hubs: Threaded, insulated and gasketed metallic for raintight connection.
5.Couplings:
Threaded straight type: Same material and finish as the conduit with which
they are used on.
6.Unions: Threaded copper free cast aluminum.
7.Conduit bodies (ells and tees):
Body: Cast copper free aluminum with threaded hubs.
Standard and mogul size.
Cover:
Clip-on type with stainless steel screws.
Gasketed or non-gasketed cast copper free aluminum.
8.8. Conduit bodies (round):
Body: Cast copper free aluminum with threaded hubs.
Cover: Threaded screw on type, gasketed, cast copper free aluminum.
9.9. Sealing fittings:
Body: Cast copper free aluminum with threaded hubs.
Standard and mogul size.
With or without drain and breather.
Fiber and sealing compound: UL listed for use with the sealing fitting.
10.Hazardous location flexible coupling (HAZ-FLEX):
Liquid tight and arc resistant.
Electrically conductive so no bonding jumper is required.
Dry and wet areas:
Bronze braided covering over flexible brass core.
Bronze end fittings.
Aluminum unions and nipples.
Corrosive areas:
Stainless steel braided covering over flexible stainless steel core.
Stainless steel end fittings.
Aluminum unions and nipples.
11.Expansion couplings:
2 inch nominal straight-line conduit movement in either direction.
4 inch nominal straight-line conduit movement in either direction.
Cast copper free aluminum with insulated bushing.
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Gasketed for wet locations.
Internally or externally grounded.
12.Expansion/deflection couplings:
3/4 IN nominal straight-line conduit movement in either direction.
30degree nominal deflection from the normal in all directions.
Metallic hubs, neoprene outer jacket and stainless steel jacket clamps.
Internally or externally grounded.
Watertight, raintight and concrete tight.
13.Standards: UL467, UL514B, UL886.
B.Fittings for Use with PVC-Aluminum:
1.The same material and construction as those fittings listed under paragraph "Fittings
for Use with Aluminum Conduit" and coated as defined under paragraph "PVC Coated
Aluminum Conduit"
PART 3 -EXECUTION
3.1RACEWAY APPLICATION
A.Outdoors: Apply raceway products as specified below, unless otherwise indicated:
1.Exposed Conduit: Aluminum rigid conduit.
2.Concealed Conduit, Above ground: Aluminum rigid conduit.
3.Underground Conduit: RNC, TypeEPC-40-PVC, concrete encased.
4.Under concrete slab: RNC, TypeEPC-40-PVC, concrete encased.
5.Concealed in Concrete: RNC, TypeEPC-40-PVC.
6.Chemical areas: PVC-coated aluminum rigid conduit .
7.Installed in wet-wells: PVC-coated aluminum rigid conduit.
8.Connection to Vibrating Equipment (Including Transformers and Hydraulic,
Pneumatic, Electric Solenoid, or Motor-Driven Equipment): PVC Coated Light-tight
Flexi able Metal Conduit.
9.Boxes and Enclosures, Aboveground: NEMA250, Type4X, stainless steel.
B.Indoors: Apply raceway products as specified below, unless otherwise indicated:
1.Exposed Conduit: Aluminum rigid conduit.
2.Concealed in Ceilings and Interior Walls and Partitions: Aluminum rigid conduit.
3.Concealed in Masonry or CMU walls: RNC, TypeEPC-80-PVC..
4.Connection to Vibrating Equipment (Including Transformers and Hydraulic,
Pneumatic, Electric Solenoid, or Motor-Driven Equipment): PVC Coated Light-tight
Flexible Metal Conduit.
5.Damp or Wet Locations: Aluminum rigid conduit.
6.Chemical areas: PVC-coated aluminum rigid conduit.
7.Boxes and Enclosures: NEMA250, Type4, except use NEMA250, Type4X, stainless
steel in damp, wet, or chemical locations.
C.Minimum Raceway Size: 3/4-inch trade size. Minimum size for underground conduit shall be
1-inch trade size.
D.Raceway Fittings: Compatible with raceways and suitable for use and location.
1.PVC Externally Coated, Aluminum Conduits: Use only fittings listed for use with that
material. Patch and seal all joints, nicks, and scrapes in PVC coating after installing
conduits and fittings. Use sealant recommended by fitting manufacturer.
E.Do not install aluminum conduits in contact with concrete.
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3.2CONDUIT BODIES AND FITTINGS AND ACCESSORIES
A.Conduit bodies and fittings shall not reduce the conduit fill area for the size of conduit to
which they are installed. The next size of conduit body or fitting shall be installed if required.
B.Conduit Seals:
1.Installed in conduit systems located in hazardous areas as required by the NFPA70.
C.Install Expansion Fittings:
1.Where conduits are exposed to the sun and conduit run is greater than 200feet.
2.Elsewhere as identified on the Drawings.
D.Install Expansion/Deflection Fittings:
1.Where conduits enter a structure.
Except electrical manholes and handholes.
Except where the ductbank is tied to the structure with rebar.
2.Where conduits span structural expansions joints.
3.Elsewhere as identified on the Drawings.
E.Threaded connections shall be made wrench-tight.
F.Conduit joints shall be watertight:
1.Where subjected to possible submersion.
2.In areas classified as wet.
3.Underground.
G.Terminate Conduits:
1.In metallic outlet boxes:
Conduit hub and locknut.
Insulated bushing and two (2) locknuts.
Use grounding type locknut or bushing when required by NFPA70.
2.In NEMA12 rated enclosures:
Watertight, insulated and gasketed hub and locknut.
Use grounding type locknut or bushing when required by NFPA70.
3.In NEMA4X rated enclosures:
Watertight, insulated and gasketed hub and locknut.
4.In NEMA 7 rated enclosures:
Into an integral threaded hub.
5.When stubbed up through the floor into floor mount equipment:
With an insulated grounding bushing on metallic conduits.
With end bells on non-metallic conduits.
3.3OUTLET, PULL AND JUNCTION BOX INSTALLATION
A.General:
1.Install products in accordance with manufacturer's instructions.
2.See the Drawings for area classifications.
3.Fill unused punched-out, tapped, or threaded hub openings with insert plugs.
4.Size boxes to accommodate quantity of conductors enclosed and quantity of conduits
connected to the box.
B.Outlet Boxes:
1.Permitted uses of metallic outlet boxes:
Housing of wiring devices:
Recessed in all stud framed walls and ceilings.
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Recessed in poured concrete, concrete block, and brick walls of
architecturally finished areas and exterior building walls.
Pull or junction box:
Above gypsum wall board or acoustical tile ceilings.
Above 10feet in an architecturally finished area where there is no ceiling.
2.Permitted uses of cast outlet boxes:
Housing of wiring devices surface mounted in non-architecturally finished dry,
wet corrosive, and hazardous areas.
Pull and junction box surface mounted in non-architecturally finished dry, wet,
and corrosive areas.
3.Permitted uses of non-metallic outlet boxes:
Housing of wiring devices surface mounted in non-architecturally finished
corrosive areas.
Pull and junction box surface mounted in non-architecturally finished corrosive
areas.
4.Mount device outlet boxes where indicated on the Drawings and at heights as
scheduled in Section262726 "Wiring Devices."
5.Set device outlet boxes plumb and vertical to the floor.
6.Outlet boxes recessed in walls:
Install with appropriate stud wall support brackets or adjustable bar hangers so
that they are flush with the face of the wall.
Locate in ungrouted cell of concrete block with bottom edge of box flush with
bottom edge of block and flush with the face of the block.
7.Place barriers between switches in boxes with 277V switches on opposite phases.
8.Back-to-back are not permitted.
9.When anoutlet box is connected to a PVC coated conduit, the box shall also be PVC
coated.
C.Pull and Junction Boxes:
1.Install pull or junction boxes in conduit runs where indicated or required to facilitate
pulling of wires or making connections.
Make covers of boxes accessible.
2.Permitted uses of NEMA4X metallic enclosure:
Pull or junction box surface mounted in areas designated as wet and/or
corrosive.
3.Permitted uses of NEMA4X non-metallic enclosure:
Pull or junction box surfaced mounted in areas designated aswet and/or highly
corrosive.
4.Permitted uses of NEMA7 enclosure:
Pull or junction box surface mounted in areas designated as Class I hazardous.
Provide PVC coating in corrosive areas when PVC coated conduit is used.
5.Permitted uses of NEMA12 enclosure:
Pull or junction box surface mounted in areas designated as dry.
3.4INSTALLATION
A.Comply with NECA1 for installation requirements applicable to products specified in Part2
except where requirements on Drawings or in this Article are stricter.
B.Keep raceways at least 6inches away from parallel runs of flues and steam or hot-water
pipes. Install horizontal raceway runs above water and steam piping.
C.Complete raceway installation before starting conductor installation.
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D.!Arrange stub-ups so curved portions of bends are not visible above the finished slab.
E.!Install no more than the equivalent of three 90-degree bends in any conduit run except for
communications conduits, for which fewer bends are allowed.
F.!Conceal conduit within finished walls, ceilings, and floors, unless otherwise indicated.
G.!Raceways Embedded or under slabs in Slabs:
1.!Run conduit larger than 1 inch trade size, parallel or at right angles to main
reinforcement. Where at right angles to reinforcement, place conduit close to slab
support.
2.!Arrange raceways to cross building expansion joints at right angles with expansion
fittings.
3.!Provide Aluminum Rigid PVC-Coated conduit bends for PVC conduits 2-inch and
larger.
4.!At the transition from PVC to rigid aluminum conduit, extend PVC Coated rigid
aluminum conduit a minimum of 6 inches into the concrete.
H.!Raceway Terminations at Locations Subject to Moisture or Vibration: Use insulating
bushings to protect conductors, including conductors smaller than No. 4 AWG.
I.!Install pull wires in empty raceways. Use polypropylene or monofilament plastic line with not
less than 200-lb. tensile strength. Leave at least 12 inches of slack at each end of pull wire.
J.!Install raceway sealing fittings at suitable, approved, and accessible locations and fill them
with listed sealing compound. For concealed raceways, install each fitting in a flush steel box
with a blank cover plate having a finish similar to that of adjacent plates or surfaces. Install
raceway sealing fittings where indicated on drawings.
K.!Expansion-deflection Fittings for Rigid Aluminum Conduit and PVC-Coated Conduit: Install in
each run of aboveground conduit crossing structural expansion joints and on exposed
conduit runs of more than 100 feet or where necessary. Provide bonding jumpers across
fittings.
L.!Flexible Conduit Connections: Use maximum of 72 inches of flexible conduit for recessed
and semi-recessed lighting fixtures; equipment subject to vibration, noise transmission, or
movement; and for transformers and motors.
M.!Recessed Boxes in Masonry Walls: Saw-cut opening for box in center of cell of masonry
block and install box flush with surface of wall.
N.!Set metal floor boxes level and flush with finished floor surface.
3.5!SLEEVE INSTALLATION FOR ELECTRICAL PENETRATIONS
A.!Coordinate sleeve selection and application with selection and application of firestopping in
accordance with applicable regulations
B.!Concrete Slabs and Walls: Install sleeves for penetrations unless core-drilled holes or
formed openings are used. Install sleeves during erection of slabs and walls.
C.!Use pipe sleeves unless penetration arrangement requires rectangular sleeved opening.
D.!Rectangular Sleeve Minimum Metal Thickness:
1.!For sleeve cross-section rectangle perimeter less than 50 inches and no side greater
than 16 inches, thickness shall be 0.052 inch.
2.!For sleeve cross-section rectangle perimeter equal to, or greater than 50 inches and
1 or more sides equal to or greater than 16 inches, thickness shall be 0.138 inch.
E.!Fire-Rated Assemblies: Install sleeves for penetrations of fire-rated floor and wall
assemblies unless openings compatible with firestop system used are fabricated during
construction of floor or wall.
F.!Cut sleeves to length for mounting flush with both surfaces of walls.
G.!Extend sleeves installed in floors 2 inches above finished floor level.
H.!Size pipe sleeves to provide 1/4-inch annular clear space between sleeve and raceway
unless sleeve seal is to be installed.
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0537-038-01 RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS JANUARY 2023
I.!Seal space outside of sleeves with grout for penetrations of concrete and masonry and with
approved joint compound for gypsum board assemblies.
J.!Interior Penetrations of Non-Fire-Rated Walls and Floors: Seal annular space between
sleeve and raceway, using joint sealant appropriate for size, depth, and location of joint.
K.!Fire-Rated-Assembly Penetrations: Maintain indicated fire rating of walls, partitions, ceilings,
and floors at raceway penetrations. Install sleeves and seal with firestop materials.
L.!Roof-Penetration Sleeves: Seal penetration of individual raceways with flexible, boot-type
flashing units applied in coordination with roofing work.
M.!Aboveground, Exterior-Wall Penetrations: Seal penetrations using sleeves and mechanical
sleeve seals. Select sleeve size to allow for 1-inch annular clear space between pipe and
sleeve for installing mechanical sleeve seals.
N.!Underground, Exterior-Wall Penetrations: Install cast-iron "wall pipes" for sleeves. Size
sleeves to allow for 1-inch annular clear space between raceway and sleeve for installing
mechanical sleeve seals.
3.6!SLEEVE-SEAL INSTALLATION
A.!Install to seal underground, exterior wall penetrations.
B.!Use type and number of sealing elements recommended by manufacturer for raceway
material and size. Position raceway in center of sleeve. Assemble mechanical sleeve seals
and install in annular space between raceway and sleeve. Tighten bolts against pressure
plates that cause sealing elements to expand and make watertight seal.
3.7!FIRESTOPPING
A.!Apply firestopping to electrical penetrations of fire-rated floor and wall assemblies to restore
original fire-resistance rating of assembly.
3.8!PROTECTION
A.!Provide final protection and maintain conditions that ensure coatings, finishes, and cabinets
are without damage or deterioration at time of Substantial Completion.
1.!Repair damage to PVC or paint finishes with matching touchup coating recommended
by manufacturer.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 05 33 - PAGE 8 OF 8 BID SET
0537-038-01 RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS JANUARY 2023
SECTION 26 05 36
CABLE TRAYS FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1!SUMMARY
A.!The work covered under this section consists of the furnishing of all necessary labor,
supervision, materials, equipment, tests and services to install complete cable tray systems
as shown on the drawings.
B.!Cable tray systems are defined to include, but are not limited to straight sections of ladder
or solid bottom type (as shown on drawings) cable trays, bends, tees, elbows, drop-outs,
supports and accessories.
C.!Drawings:
1.!The drawings, which constitute a part of these specifications, indicate the general
route of the cable runway systems. Data presented on these drawings is as accurate
as preliminary surveys and planning can determine until final equipment selection is
made. Accuracy is not guaranteed and field verification of all dimensions, routing, etc.,
is required.
2.!Specifications and drawings are for assistance and guidance, but exact routing,
locations, distances and levels will be governed by actual field conditions.
CONTRACTOR is directed to make field surveys as part of his work prior to submitting
system layout drawings.
1.2!REFERENCES
A.!ASTM International:
1.!ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on
Iron and Steel Products.
2.!ASTM A653/A653M - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized)
or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process.
3.!ASTM A1011 Specification for Steel, Sheet and Strip, Hot- Rolled, Carbon, Structural,
High-Strength Low-Alloy and High Strength Low Alloy with Improved Formability
(Formally ASTM A570 & A607).
4.!ASTM A1008 Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, high-
Strength Low-Alloy and high-Strength Low-Alloy with Improved Formability (Formally
ASTM A611).
5.!ASTM B633 Specification for Electrodeposited Coatings of Zinc on Iron and Steel.
B.!National Electrical Manufacturers Association:
1.!NEMA FG 1 - Nonmetallic Cable Tray Systems.
2.!NEMA VE 1-1998 - Metal Cable Tray Systems.
3.!NEMA VE 2-2000 - Cable Tray Installation Guidelines.
1.3!ADMINISTRATIVE REQUIREMENTS - NOT USED
1.4!SUBMITTALS
PLUMMER ASSOCIATES, INC. 26 05 36 - PAGE 1 OF 4 90% REVIEW SET
0537-038-01 CABLE TRAYS FOR ELECTRICAL SYSTEMS APRIL 2022
A.!Shop Drawings: Indicate tray type, dimensions, support points, and finishes.
B.!Product Data: Submit fittings and accessories.
C.!Manufacturer's Installation Instructions: Submit application conditions and limitations of use
stipulated by product testing agency specified under Regulatory Requirements. Include
instructions for storage, handling, protection, examination, preparation, and installation of
product.
1.5!QUALITY ASSURANCE
A.!Manufacturers:
1.!Firms regularly engaged in manufacture of cable trays and fittings of types and
capacities required, whose products have been in satisfactory use in similar service for
not less than 5 years.
2.!Manufacturer: Company specializing in manufacturing products specified in this
section with minimum 10 years of documented experience, and with service facilities
within 500 miles of Project.
B.!NEMA Compliance: Comply with NEMA Standards Publication Number VE1, "Cable Tray
Systems."
C.!NEC Compliance: Comply with NEC, as applicable to construction and installation of cable
tray and cable channel systems (Article 318, NEC).
D.!DUL Compliance: Provide products that are UL-classified and labeled.
E.!NFPA Compliance: Comply with NFPA 70B, "Recommended Practice for Electrical
Equipment Maintenance" pertaining to installation of cable tray systems.
1.6!DELIVERY, STORAGE, AND HANDLING
A.!Deliver cable tray systems and components carefully to avoid breakage, denting and scoring
finishes. Do not install damaged equipment.
1.!Store cable trays and accessories in original cartons and in clean dry space; protect
from weather and construction traffic. Wet materials should be unpacked and dried
before storage.
1.7!SITE CONDITIONS - NOT USED
1.8!WARRANTY - NOT USED
PART 2 - PRODUCTS
2.1!ACCEPTABLE MANUFACTURERS
A.!Subject to compliance with these specifications, cable tray systems to be installed shall be as
manufactured by the following:
1.!Cooper B-Line, Inc.
2.!Cope, T. J., Inc.; a subsidiary of Allied Tube & Conduit.
3.!GS Metals Corp.; GLOBETRAY Products.
4.!MONO-SYSTEMS, Inc.
PLUMMER ASSOCIATES, INC. 26 05 36 - PAGE 2 OF 4 90% REVIEW SET
0537-038-01 CABLE TRAYS FOR ELECTRICAL SYSTEMS APRIL 2022
5.!MPHusky.
6.!PW Industries.
2.2!CABLE TRAY SECTIONS AND COMPONENTS
A.!General: Except as otherwise indicated, provide metal cable trays, of types, classes and
sizes indicated; with splice plates, bolts, nuts and washers for connecting units. Construct
units with rounded edges and smooth surfaces; in compliance with applicable standards;
and with the following additional construction features.
B.!Materials and Finish: Material and finish specifications for each tray type are as follows:
C.!Aluminum: Straight section and fitting side rails and rungs shall be extruded from Aluminum
Association Alloy 6063. All fabricated parts shall be made from Aluminum Association
Alloy 5052.
2.3!TYPE OF TRAY SYSTEM
A.!Ladder type trays shall consist of 2 longitudinal members (side rails) with transverse
members (rungs) welded to the side rails. Rungs shall be spaced 9 inches on center. Spacing
in radiused fittings shall be 9 inches and measured at the center of the tray's width. Rungs
shall have a minimum cable-bearing surface of 7/8 inch with radiused edges. No portion of
the rungs shall protrude below the bottom plane of the side rails.
B.!Solid bottom trough type trays shall consist of two longitudinal members (side rails) with a
corrugated bottom welded to the side rails. The peaks of the corrugated bottom shall have a
minimum flat cable-bearing surface of 2-3/4 inch and shall be spaced 6 inches on center.
C.!Tray Sizes shall have 5 inch minimum usable load depth, or as noted on the drawing.
D.!Straight tray sections shall have side rails fabricated as I-Beams. All straight sections shall be
supplied in standard 12-foot lengths, except where shorter lengths are permitted to
facilitate tray assembly lengths as shown on drawings.
E.!Tray widths shall be as shown on drawings.
F.!All fittings must have a 3 inch tangent and a minimum radius of 12 inches.
G.!Splice plates shall be the bolted type made as indicated below for each tray type. The
resistance of fixed splice connections between adjacent sections of tray shall not exceed
0.00033 late construction shall be such that a splice may be located anywhere
within the support span without diminishing rated loading capacity of the cable tray.
1.!Aluminum Tray - Splice plates shall be made of 6063-T6 aluminum, using 4 square
neck carriage bolts and serrated flange locknuts. Hardware shall be zinc plated in
accordance with ASTM B633, SC1. If aluminum cable tray is to be used outdoors, then
hardware shall be Type 316 stainless.
H.!Splice plates shall be furnished with straight sections and fittings.
I.!Cable Tray Supports: Shall be placed so that the support spans do not exceed maximum
span indicated on drawings. Supports shall be constructed from 12-gauge steel formed
shape channel members 1-5/8x1-5/8 inch with necessary hardware such as Trapeze Support
Kits as manufactured by Cooper B-Line, Inc. or engineer approved equal. Cable trays
installed adjacent to walls shall be supported on wall mounted brackets such as B409 as
PLUMMER ASSOCIATES, INC. 26 05 36 - PAGE 3 OF 4 90% REVIEW SET
0537-038-01 CABLE TRAYS FOR ELECTRICAL SYSTEMS APRIL 2022
manufactured by Cooper B-Line, Inc. or engineer approved equal.
J.!Trapeze hangers supports shall be supported by 1/2-inch (minimum) diameter stainless steel
rods.
K.!Barrier Strips: Shall be placed as specified on drawings and be fastened into the tray with
self-drilling screws.
L.!Accessories - special accessories shall be furnished as required to protect, support, and
install a cable tray system. Accessories shall consist of but are not limited to; section splice
plates, expansion plates, blind-end plates, specially designed ladder dropouts, barriers, etc.
M.!Covers: Cable trays located outside or under platforms shall have peaked flanged covers.
2.4!LOADING CAPACITIES
A.!Cable tray shall be capable of carrying a uniformly distributed load of 75 lb/ft on a 10-foot
support span with a safety factor of 1.5 when supported as a simple span and tested per
NEMA VE1 Section 5.2.
PART 3 - EXECUTION
3.1!INSTALLATION
A.!Install cable trays as indicated: Installation shall be in accordance with equipment
manufacturer's instructions, and with recognized industry practices to ensure that cable tray
equipment comply with requirements of NEC and applicable portions of NFPA 70B.
Reference NEMA VE2 for general cable tray installation guidelines.
B.!Coordinate cable tray with other electrical work as necessary to properly integrate
installation of cable tray work with other work.
C.!Provide sufficient space encompassing cable trays to permit access for installing and
maintaining cables.
D.!Cable tray fitting supports shall be located such that they meet the strength requirements of
straight sections. Install fitting supports per NEMA VE-2 guidelines, or in accordance with
manufacturer's instructions.
E.!Cable tray should be free of burrs and sharp edges.
F.!Cable tray shall be grounded according to manufacturer's specifications.
3.2!TESTING
A.!Test cable trays to ensure electrical continuity of bonding and grounding connections, and
to demonstrate compliance with specified maximum grounding resistance. See NFPA 70B
Chapter 18 for testing and test methods.
B.!Manufacturer shall provide test reports witnessed by an independent testing laboratory of
the "worst case" loading conditions outlined in this specification and performed in
accordance with the latest revision of NEMA VE-1; including test reports verifying rung load
capacity in accordance with NEMA VE-1 Section 5.4.
END OF SECTION
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0537-038-01 CABLE TRAYS FOR ELECTRICAL SYSTEMS APRIL 2022
SECTION 26 05 43
UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1!SUMMARY
A.!This Section includes the following:
1.!Conduit, ducts, and duct accessories for concrete-encased duct banks, and in single
duct runs.
2.!Handholes and boxes.
3.!Manholes.
1.2!DEFINITIONS
A.!RNC: Rigid nonmetallic conduit.
1.3!SUBMITTALS
A.!Product Data: For the following:
1.!Duct-bank materials, including separators and miscellaneous components.
2.!Ducts and conduits and their accessories, including elbows, end bells, bends, fittings,
and solvent cement.
3.!Accessories for manholes, handholes, and boxes.
4.!Warning tape.
5.!Conduit markers.
B.!Shop Drawings for Precast or Factory-Fabricated Underground Utility Structures: Include
plans, elevations, sections, details, attachments to other work, and accessories, including
the following:
1.!Duct entry provisions, including locations and duct sizes.
2.!Reinforcement details.
3.!Frame and cover design and manhole frame support rings.
4.!Ladder details.
5.!Grounding details.
6.!Dimensioned locations of cable rack inserts, pulling-in and lifting irons, and sumps.
7.!Joint details.
C.!Shop Drawings for Factory-Fabricated Handholes and Boxes Other Than Precast Concrete:
Include dimensioned plans, sections, and elevations, and fabrication and installation details,
including the following:
1.!Duct entry provisions, including locations and duct sizes.
2.!Cover design.
3.!Grounding details.
4.!Dimensioned locations of cable rack inserts, and pulling-in and lifting irons.
D.!Duct-Bank Coordination Drawings: Show duct profiles and coordination with other utilities
and underground structures.
1.!Include plans and sections, drawn to scale, and show bends and locations of
expansion fittings.
E.!Product Certificates: For concrete and steel used in precast concrete manholes and
handholes, ASTM C 858.
PLUMMER ASSOCIATES, INC. 26 05 43 - PAGE 1 OF 10 BID SET
0537-038-01 UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS JANUARY 2023
1.4!QUALITY ASSURANCE
A.! C2.
B.! 70.
1.5!DELIVERY, STORAGE, AND HANDLING
A.!Deliver ducts to Project site with ends capped. Store nonmetallic ducts with supports to
prevent bending, warping, and deforming.
B.!Store precast concrete underground utility structures at Project site as recommended by
manufacturer to prevent physical damage. Arrange so identification markings are visible.
C.!Lift and support precast concrete units only at designated lifting or supporting points.
1.6!PROJECT CONDITIONS
A.!Interruption of Existing Electrical Service: When applicable, do not interrupt electrical
service to facilities occupied by Owner or others unless permitted under the following
conditions and then only after arranging to provide temporary electrical service according to
requirements indicated:
1.!Notify ENGINEER no fewer than two days in advance of proposed interruption of
electrical service.
2.!Do not proceed with
permission.
1.7!COORDINATION
A.!Coordinate layout and installation of ducts, manholes, handholes, and boxes with final
arrangement of other utilities, site grading, and surface features as determined in the field.
B.!Coordinate elevations of ducts and duct-bank entrances into manholes, handholes, and
boxes with final locations and profiles of ducts and duct banks as determined by
coordination with other utilities, underground obstructions, and surface features. Revise
locations and elevations from those indicated as required to suit field conditions and to
ensure that duct runs drain to manholes and handholes, and as approved by ENGINEER.
PART 2 - PRODUCTS
2.1!PVC COATED ALUMINUM CONDUIT
A.!Available Manufacturers: Subject to compliance with requirements, manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.!American Conduit, by SAPA
2.!OCAL, Inc.
3.!Perma-Cote
B.!PVC-Coated Aluminum Rigid Conduit:
1.!Alloy: Manufactured of 6063 alloy in temper designation T-1.
2.!Standards: UL 6A, "Standard for Electrical Rigid Metal Conduit - Aluminum, Red Brass
and Stainless Steel" and is manufactured to ANSI C80.5.
3.!Coating Thickness: 0.040 inch, minimum.
2.2!PVC CONDUIT
A.!RNC: Conforming to NEMA TC 2, Type EPC-40-PVC, UL 651, with matching fittings by same
manufacturer as the conduit, complying with NEMA TC 3 and UL 514B.
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0537-038-01 UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS JANUARY 2023
2.3NONMETALLIC DUCTS AND DUCT ACCESSORIES
A.Available Manufacturers: Subject to compliance with requirements, manufacturersoffering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.ARNCO Corp.
2.Beck Manufacturing.
3.Cantex, Inc.
4.CertainTeed Corp.; Pipe & Plastics Group.
5.Condux International, Inc.
6.ElecSys, Inc.
7.Electri-Flex Company.
8.IPEX Inc.
9.Lamson & Sessions; Carlon Electrical Products.
10.Manhattan/CDT; a division of Cable Design Technologies.
11.Spiraduct/AFC Cable Systems, Inc.
B.Duct Accessories:
1.Duct Separators: Factory-fabricated rigid PVC interlocking spacers, sized for type and
sizes of ducts with which used, and selected to provide minimum duct spacing
indicated while supporting ducts during concreting or backfilling.
2.4DETECTABLE WARNING TAPE
A.Description: Acid-and alkali-resistant polyethylene film warning tape manufactured for
marking and identifying underground utilities, a minimum of 6inches wide and 4mils thick,
continuously inscribed with a description of the utility, with metallic core encased in a
protective jacket for corrosion protection, detectable by metal detector when tape is buried
up to 30inches deep. Tape shall be red in color for electrical, orange in color for
communication. Printed legend shall indicate type of underground line
2.5PRECAST MANHOLES
A.Available Manufacturers: Subject to compliance with requirements, manufacturersoffering
products that may be incorporated into the work include, but are not limited to, the
following:
1.Carder Concrete Products.
2.Christy Concrete Products.
3.Elmhurst-Chicago Stone Co.
4.Oldcastle Precast Group.
5.Riverton Concrete Products; a division of Cretex Companies, Inc.
6.Utility Concrete Products, LLC.
7.Utility Vault Co.
8.Wausau Tile, Inc.
B.Comply with ASTMC858, with AASHTOH-17, H-20 structural design load rating, and with
interlocking mating sections, complete with accessories, hardware,and features.
1.Windows: Precast openings in walls, arranged to match dimensions and elevations of
approaching ducts and duct banks plus an additional 12inches vertically and
horizontally to accommodate alignment variations.
Windows shall be located no less than 6inches from interior surfaces of walls,
floors, or roofs of manholes, but close enough to corners to facilitate racking of
cables on walls.
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0537-038-01UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMSJANUARY 2023
Window opening shall have cast-in-place, welded wire fabric reinforcement for
field cutting and bending totie in to concrete envelopes of duct banks.
Window openings shall be framed with at least two additional No.4 steel
reinforcing bars in concrete around each opening.
C.Concrete Knockout Panels: 1-1/2 to 2inches thick for future conduit entrance and sleeve
for ground rod.
D.Joint Sealant: Asphaltic-butyl material with adhesion, cohesion, flexibility, and durability
properties necessary to withstand maximum hydrostatic pressures at the installation location
with the ground-water level at grade.
2.6UTILITY STRUCTURE ACCESSORIES
A.Available Manufacturers: Subject to compliance with requirements, manufacturersoffering
products that may be incorporated into the work include, but are not limited to, the
following:
1.Bilco Company (The).
2.Campbell Foundry Company.
3.Carder Concrete Products.
4.Christy Concrete Products.
5.East Jordan Iron Works, Inc.
6.Elmhurst-Chicago Stone Co.
7.McKinley Iron Works, Inc.
8.Neenah Foundry Company.
9.NewBasis.
10.Oldcastle Precast Group.
11.Osburn Associates, Inc.
12.Pennsylvania Insert Corporation.
13.Riverton Concrete Products; a division of Cretex Companies, Inc.
14.Strongwell Corporation; Lenoir City Division.
15.Underground Devices, Inc.
16.Utility Concrete Products, LLC.
17.Utility Vault Co.
18.Wausau Tile, Inc.
B.Manhole Access Covers, and Chimney Components: Comply with structural design loading
specified for manhole.
C.Access Covers:
Designed for incidental H-20 Wheel Loading
Torsion Bar Assist opening with safety latch to prevent accidental closing.
Size36x36inches
Weatherproof steel frame, with steel cover with recessed cover hook eyes and
tamper-resistant, captive, cover-securing bolts.
Similar to Jensen Precast CAA-3636
Configuration: Imbedded into top ring cover
2.Manhole Chimney Components: Precast concrete rings with dimensions matched to
those of the manhole.
D.Manhole Sump Frame and Grate: ASTMA48/A48M, Class30B, gray cast iron.
E.Pulling Eyes in Concrete Walls: Eyebolt with reinforcing-bar fastening insert, 2-inch
diameter eye, and 1x4-inch bolt.
1.Working Load Embedded in 6-Inch, 4,000-psi Concrete: 13,000lbft minimum
tension.
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0537-038-01UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMSJANUARY 2023
F.Pulling-In and Lifting Irons in Concrete Floors: 7/8-inchdiameter, hot-dip galvanized, bent
steel rod; stress relieved after forming; and fastened to reinforcing rod. Exposed triangular
opening.
1.Ultimate Yield Strength: 40,000lbft shear and 60,000lbft tension.
G.Bolting Inserts for Concrete Utility Structure Cable Racks and Other Attachments: Flared,
threaded inserts of noncorrosive, chemical-resistant, nonconductive thermoplastic material;
1/2x2-3/4 inches deep, flared to 1-1/4 inches minimum at base.
1.Tested Ultimate Pullout Strength: 12,000lbft minimum.
H.Expansion Anchors for Installation after Concrete Is Cast: Zinc-plated, carbon-steel-wedge
type with stainless-steel expander clip with 1/2-inch bolt, 5,300lbft rated pullout strength,
and minimum 6,800-lbft rated shear strength.
I.Cable Rack Assembly: Nonmetallic. Components fabricated from nonconductive, fiberglass-
reinforced polymer.
1.Stanchions: Nominal 36 inches high x4inches wide, with a minimum of 9holes for
arm attachment.
2.Arms: Arranged for secure, drop-in attachment in horizontal position at any location
on cable stanchions, and capable of being locked in position. Arms shall be available
in lengths ranging from 3inches with 450lb. minimum capacity to 20inches with
250lb. minimum capacity. Top of arm shall be nominally 4inches wide, and arm shall
have slots along full length for cable ties.
J.Duct-Sealing Compound: Nonhardening, safe for contact withhuman skin, not deleterious
to cable insulation, and workable at temperatures as low as 35°F. Capable of withstanding
temperature of 300°F without slump and adhering to clean surfaces of plastic ducts, metallic
conduits, conduit coatings, concrete, masonry, lead, cable sheaths, cable jackets, insulation
materials, and common metals.
K.Fixed Manhole Ladders: Arranged for attachment to roof of manhole. Ladder and mounting
brackets and braces shall be fabricated from nonconductive, structural-grade, fiberglass-
reinforced resin.
L.Cover Hooks: Heavy duty, designed for lifts 60 lbft and greater. Two required.
2.7UNDERGROUND DUCTS STEEL REINFORCEMENT
A.Reinforcing Bars: ASTMA615, Grade60, deformed.
B.Plain-Steel Wire: ASTMA82, as drawn.
C.Plain-Steel Welded Wire Reinforcement: ASTMA185, fabricated from as-drawn steel wire
into flat sheets.
D.Deformed-Steel Welded Wire Reinforcement: ASTMA497, flat sheet.
2.8UNDERGROUND DUCTS CONCRETE
A.Materials
1.Cementitious Material: Use the following cementitious materials, of the same type,
brand, and source throughout Project:
2.Portland Cement: ASTMC150, TypeII or Type 1/II.Supplement with the following:
Fly Ash: ASTMC618, ClassC. Fly ash may be used for replacement of up to
15% of cement content by weight except for paving concrete.
3.Normal-Weight Aggregate: ASTMC33, graded, 1inch nominal maximum aggregate
size.
4.Water: ASTMC94;potable.
B.Concrete Mixtures
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1.!Comply with ACI 301 requirements for concrete mixtures.
2.!Provide concrete with the following mix design to result in concrete placed in the field
of minimum compressive strength of 3,000 psi at 28 days based on test cylinders
which are taken during concrete placement.
Unit Measurement
Minimum Compressive Strength (7 day) 2,250 psi
Minimum Compressive Strength (28 day) 3,000 psi
Coarse Aggregate ASTM C33, No. 467
Fine Aggregate ASTM C33
Water/Cementious Ratio (max.) 0.50 by weight
Air Entrainment 4-6 percent
Slump with Superplasticizer 7 inches to 9 inches
Slump without Superplasticizer 3 inches 1 inch
Minimum Cementious Content 470 pounds per cubic yard
C.!Additive
1.! Red ferrous oxide concrete coloring pigment mixed at the rate of 1-1/2 lb. per sack
of cement for electrical conduit.
2.9!GROUNDING
A.!Bare Copper Conductors: Shall be tinned, stranded Conductors complying with ASTM B 8
and Tinned Conductors: ASTM B 33.
B.!Welded Connectors: Exothermic-welding kits of types recommended by kit manufacturer for
materials being joined and installation conditions. Listed and labeled by a nationally
recognized testing laboratory acceptable to authorities having jurisdiction for applications in
which used, and for specific types, sizes, and combinations of conductors and other items
connected.
C.!Ground Rods: Copper-clad steel; 3/4 inch by 10 feet in length.
2.10!SOURCE QUALITY CONTROL
A.!Test and inspect precast concrete utility structures according to ASTM C 1037.
1.!Strength tests of complete boxes and covers shall be by either an independent testing
agency or the manufacturer. A qualified registered professional engineer shall certify
tests by manufacturer.
2.!Testing machine pressure gages shall have current calibration certification complying
with ISO 9000 and ISO 10012, and traceable to NIST standards.
PART 3 - EXECUTION
3.1!UNDERGROUND DUCT APPLICATION
A.!Ducts shall be RNC, NEMA Type EPC-40-PVC, in reinforced, concrete-encased duct bank,
unless otherwise indicated.
3.2!EARTHWORK
A.!Excavation
1.!Protect structures, utilities, sidewalks, pavements, and other facilities from damage
caused by settlement, lateral movement, undermining, washout, and other hazards
created by excavation for trenches.
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0537-038-01 UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS JANUARY 2023
2.!During inclement weather and where site conditions warrant, take precautions to
prevent surface-water run-off from entering the excavation. Remove and dispose of
water entering trench, as necessary grade trench bottom and compact subgrade. Do
not place bedding, lay pipe, conduits, cables, or duct banks in water. Provide
continuous control of water until trench backfill is complete.
3.!Excavate to lines, grades, depths, and dimensions shown and as necessary to
accomplish Work. Allow for excavation support and protection materials, working
space, bedding course, topsoil, and related materials.
4.!Excavate trenches to uniform widths to provide required clearance of each side of
conduit. Trench walls shall be vertical to elevation equal to 12 inches above top of
conduits or duct banks.
5.!Precede with caution in areas of existing utilities exposing them by hand excavation or
other means acceptable to utility owner. Protect, support, and maintain existing
utilities.
6.!Avoid disturbing soil within branch spread of trees designated for protection. If it is
necessary to excavate through roots, perform work by hand and cut roots with a
sharp axe.
B.!Preparation of Trench Bottom
1.!Subgrade: Grade with hand tools, remove loose and disturbed materials, and trim off
high areas left by excavating bucket teeth. Allow space for bedding material as
required.
2.!Soft Subgrade: Remove any soft subgrade, replacing with trench stabilizing material.
3.3!DUCT INSTALLATION
A.!Slope: Pitch ducts a minimum slope of 1:300 down toward manholes and handholes and
away from buildings and equipment. Slope ducts from a high point in runs between two
manholes to drain in both directions.
B.!Curves and Bends: Use 5 degree angle couplings for small changes in direction. Use
manufactured long sweep bends with a minimum radius of 48 inches for feeders 600 V and
less and 25 feet for feeders above 600 V, both horizontally and vertically, at other locations,
unless otherwise indicated.
C.!Joints: Use solvent-cemented joints in ducts and fittings and make watertight according to
manufacturer
in same plane.
D.!Duct Entrances to Manholes and Concrete Handholes: Use end bells, spaced approximately
10 inches on center for 5-inch ducts, and vary proportionately for other duct sizes.
1.!Begin change from regular spacing to end-bell spacing 10 feet from the end bell
without reducing duct line slope and without forming a trap in the line.
2.!Grout end bells into structure walls from both sides to provide watertight entrances.
3.!Tie duct bank reinforcing steel into dowels at manhole walls.
E.!Wall Penetrations: Make a transition from underground duct to PVC coated-aluminum
conduit at least 10 feet outside the wall without reducing duct line slope away from the
building, and without forming a trap in the line. Use fittings manufactured for duct-to-
conduit transition. Install conduit penetrations of walls in accordance with
Division 26 Section 26 05
F.!Sealing: Provide temporary closure at terminations of ducts that have cables pulled. Seal
spare ducts at terminations. Use sealing compound and plugs to withstand at least 15 psig
hydrostatic pressure.
G.!Pulling Cord: Install 100 lb ft test nylon cord in ducts, including spares.
H.!Concrete-Encased Ducts: Support ducts on duct separators.
PLUMMER ASSOCIATES, INC. 26 05 43 - PAGE 7 OF 10 BID SET
0537-038-01 UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS JANUARY 2023
1.Separator Installation: Space separators close enough to prevent sagging and
deforming of ducts, with not less than 4 spacers per 20 feet of duct. Secure
separators to earth and to ducts to prevent floating during concreting. Stagger
separators approximately 6inches between tiers. Tie entire assembly together using
fabric straps; do not use tie wires or reinforcing steel that may form conductive or
magnetic loops around ducts or duct groups.
2.Concreting Sequence: Pour each run of envelope between manholes or other
terminations in one continuous operation.
Start at one end and finish at the other, allowing for expansion and contraction
of ducts as their temperature changes during and after the pour. Use
expansion fittings installed according to manufacturer's written
recommendations or use other specific measures to prevent expansion-
contraction damage.
3.Pouring Concrete: Spade concrete carefully during pours to prevent voids under and
between conduits and at exterior surface of envelope. Do not allow a heavy mass of
concrete to fall directly onto ducts. Use a plank to direct concrete down sides of bank
assembly to trench bottom. Allow concrete to flow to center of bank and rise up in
middle, uniformly filling all open spaces. Do not use power-driven agitating equipment
unless specifically designed for duct-bank application.
4.Reinforcement: Reinforce concrete-encased duct banks as shown on Drawings.
5.Forms: Use walls of trench to form sidewalls of duct bank where soil is self-
supporting and concrete envelope can be poured without soil inclusions; otherwise,
use forms.
6.Minimum Space between Ducts: 3inches between ducts and exterior envelope wall,
2inches between ducts for like services, and 6inches between power and signal
ducts.
7.Depth: Install top of duct bank at least 24inches below finished grade in areas not
subject to deliberate traffic and at least 30inches below finished grade in deliberate
traffic paths for vehicles unless otherwise indicated.
8.Stub-Ups: Use PVC coated-aluminum conduit elbows for stub-ups at poles and
equipment and at building entrances through the floor.
Couple PVC coated-aluminum conduits to ducts with adapters designed for this
purpose and encase coupling with 3inches of concrete.
Stub-Ups to Equipment: For equipment mounted on outdoor concrete bases,
extend PVC coated-aluminum conduit horizontally a minimum of 60inches from
edge of base. Install insulated grounding bushings on terminations at
equipment.
I.Underground-Line Warning Tape
1.During backfilling of trenches install continuous underground-line warning tape
directly above line at 6to8inches below finished grade. Use multiple tapes where
width of multiple lines installed in a common trench or concrete envelopeexceeds
16inches overall.
3.4BACKFILL
A.General:
1.Process excavated material to meet specified soil fill requirements. Adjust moisture as
necessary to obtain specified compaction. Place and compact backfill in 8-inch loose
lifts.
2.Do not allow backfill to free-fall into the trench or allow heavy, sharps pieces of
material to be placed as backfill until after 2feet of backfill has been placed.
PLUMMER ASSOCIATES, INC.26 05 43-PAGE 8OF 10BID SET
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3.!Do not use power-driven impact type compactors until at least 4 feet of backfill is
place over top of pipe.
4.!Backfill to grade with allowances for topsoil, crushed rock surfacing, pavements, or
other work.
5.!Settling backfill by jetting or flooding will only be permitted as shown on the Drawings
or when approved by Engineer in writing. Trenches improperly backfilled and
compacted, or where settlement occurs, shall be excavated to depth required,
backfilled, compacted, and surface restored to required grade.
B.!Density Control
1.!Areas Subjected to or Influenced by Vehicular Traffic. Unless otherwise indicated on
the Drawings, compact backfill to a minimum 100% of maximum density as
determined in accordance with ASTM D698, with required moisture content within
minus 2 to plus 4 of optimum.
2.!Areas Not Subjected to or Influenced by Vehicular Traffic. Unless otherwise indicated
on the Drawings, compact backfill to a minimum 95% of maximum density as
determined in accordance with ASTM D698, with required moisture content within
minus 2 to plus 4 of optimum.
3.5!UNDERGROUND CONDUIT MARKERS
A.!Mark underground duct banks 24x24x4 inch concrete marker with etched lettering and
arrows indicating the duct bank route.
B.!Install markers at point of origin, at point of termination, at bends, and at 100-foot intervals,
even if not shown on plans.
3.6!INSTALLATION OF CONCRETE MANHOLES, HANDHOLES, AND BOXES
A.!Elevations:
1.!Manhole Roof: Install with rooftop at least 6 inches above finished grade. In paved
areas and trafficways, set manhole roofs 1 inch above finished. Set other manhole
frames 1 inch above finished grade.
B.!Drainage: Install drains in bottom of manholes where indicated. Coordinate with drainage
provisions indicated.
C.!Hardware: Install removable hardware, including pulling eyes, cable stanchions, cable arms,
and insulators as required for installation; and support of cables and conductors and as
indicated.
D.!Fixed Manhole Ladders: Arrange to provide for safe entry with maximum clearance from
cables and other items in manholes.
E.!Field-Installed Bolting Anchors in Manholes and Concrete Handholes: Do not drill deeper
than 3-7/8 inches for manholes and 2 inches for handholes, for anchor bolts installed in the
field. Use a minimum of two anchors for each cable stanchion.
F.!Warning Sign: Install "Confined Space Hazard" warning sign on the inside surface of each
manhole cover.
3.7!GROUNDING
A.!Conductors: Install solid conductor for No. 8 AWG and smaller, and stranded conductors for
No. 6 AWG and larger, unless otherwise indicated.
B.!Underground Grounding Conductors: Install bare tinned-copper conductor, No. 4/0 AWG
minimum. Bury 12 inches above duct bank when indicated as part of duct-bank installation.
PLUMMER ASSOCIATES, INC. 26 05 43 - PAGE 9 OF 10 BID SET
0537-038-01 UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS JANUARY 2023
C.!Isolated Grounding Conductors: Green-colored insulation with continuous yellow stripe. On
feeders with isolated ground, identify grounding conductor where visible to normal
inspection, with alternating bands of green and yellow tape, with at least three bands of
green and two bands of yellow.
D.!Grounding Underground Distribution System Components
1.!Comply with IEEE C2 grounding requirements.
2.!Grounding Manholes and Handholes: Install a driven ground rod through manhole or
handhole floor, close to wall, and set rod depth so 4 inches will extend above finished
floor. If necessary, install ground rod before manhole is placed and provide
No. 4/0 AWG bare, tinned-copper conductor from ground rod into manhole through a
waterproof sleeve in manhole wall. Protect ground rods passing through concrete
floor with a double wrapping of pressure-sensitive insulating tape or heat-shrunk
insulating sleeve from 2 inches above to 6 inches below concrete. Seal floor opening
with waterproof, nonshrink grout.
3.!Grounding Connections to Manhole Components: Bond exposed-metal parts such as
inserts, cable racks, pulling irons, ladders, and cable shields within each manhole or
handhole, to ground rod or grounding conductor. Make connections with No. 4 AWG
minimum, stranded, hard-
plumb around corners and fasten to manhole walls. Connect to cable armor and cable
shields as recommended by manufacturer of splicing and termination kits.
E.!INSTALLATION
1.!Grounding Conductors: Route along shortest and straightest paths possible, unless
otherwise indicated or required by Code. Avoid obstructing access or placing
conductors where they may be subjected to strain, impact, or damage.
2.!Ground Rods: Drive rods until tops are 2 inches below finished floor or final grade,
unless otherwise indicated.
3.!Interconnect ground rods with grounding electrode conductor below grade and as
otherwise indicated. Make connections without exposing steel or damaging coating, if
any.
3.8!FIELD QUALITY CONTROL
A.!Perform the following tests and inspections and prepare test reports:
1.!Demonstrate capability and compliance with requirements on completion of
installation of underground ducts and utility structures.
2.!Pull aluminum or wood test mandrel through duct to prove joint integrity and test for
out-of-round duct. Provide mandrel equal to 80% fill of duct. If obstructions are
indicated, remove obstructions and retest.
3.!Test manhole and handhole grounding to ensure electrical continuity of grounding
and bonding connections
B.!Correct deficiencies and retest as specified above to demonstrate compliance.
3.9!CLEANING
A.!Pull leather-washer-type duct cleaner, with graduated washer sizes, through full length of
ducts. Follow with rubber duct swab for final cleaning and to assist in spreading lubricant
throughout ducts.
B.!Clean internal surfaces of manholes, including sump. Remove foreign material.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 05 43 - PAGE 10 OF 10 BID SET
0537-038-01 UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS JANUARY 2023
SECTION 26 05 53
IDENTIFICATION FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1!SUMMARY
A.!This Section includes the following:
B.!Identification for raceway.
C.!Identification for conductors and communication and control cable.
D.!Warning labels and signs.
E.!Instruction signs.
F.!Equipment identification labels.
G.!Miscellaneous identification products.
1.2!SUBMITTALS
A.!Product Data: For each electrical identification product indicated.
B.!Identification Schedule: An index of nomenclature of electrical equipment and system
components used in identification signs and labels.
C.!Samples: For each type of label and sign to illustrate size, colors, lettering style, mounting
provisions, and graphic features of identification products.
1.3!QUALITY ASSURANCE
A.!Comply with ANSI A13.1 and ANSI C2.
B.!Comply with NFPA 70.
C.!Comply with 29 CFR 910.145.
1.4!COORDINATION
A.!Coordinate identification names, abbreviations, colors, and other features with requirements
in the Contract Documents, Shop Drawings, Manufacturer's wiring diagrams, and the
Operation and Maintenance Manual, and with those required by codes, standards, and
29 CFR 1910.145. Use consistent designations throughout Project.
B.!Coordinate installation of identifying devices with completion of covering and painting of
surfaces where devices are to be applied.
C.!Coordinate installation of identifying devices with location of access panels and doors.
D.!Install identifying devices before installing acoustical ceilings and similar concealment.
PART 2 - PRODUCTS
2.1!SYSTEM DESCRIPTION
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.!Device nameplates information:
PLUMMER ASSOCIATES, INC. 26 05 53 - PAGE 1 OF 9 BID SET
0537-038-01 IDENTIFICATION FOR ELECTRICAL SYSTEMS JANUARY 2023
Designations as indicated on the Drawings and identified on the Process and
Instrumentation Drawings.
Device tag and loop number ID (#) (e.g. EDV-#).
Circuit ID (e.g. LPA-11).
Area served (e.g. Lighting Chemical Building).
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:
Wire numbers shall correspond to the wire numbers on the control drawings or
the panel and circuit numbers for receptacles and lighting.
Wire numbers shall correspond to the terminal block number to which they are
attached in the control panel.
Internal panel wires on a common terminal shall have the same wire number.
2.Provide the following wiring numbering schemes throughout the project for field wires
between programmable logic controllers, (PLC), vendor control panels, (CP), motor
control centers, (MCC), field starters, field instruments, etc.
Where:
ORIGIN LOC.= Designation for originating panel or device
ORIGIN TERM.= Terminal designation at originating panel or device
DEST. LOC.= Designation for destination panel or device
DEST. TERM.= Terminal designation at destination panel or device or
PLC I/O address at destination panel
Identify equipment and field instruments as the origin.
PLCs are always identified as the destination.
Location is the panel designation for CP, LCP, or PLC. For connections to MCCs,
location is the specific starter tag and loop number. Location is the tag and
loop number for motor starters, field instruments, and equipment. Any hyphen
in the panel designation or tag and loop number shall be omitted.
Terminal designation is the actual number on the terminal block where the
conductor terminates at field devices and vendor control panels. For multi-
conductor cables, all terminal numbers shall be shown, separated by commas.
Terminal designations at motor leads shall be t
standard terminal designation (e.g. T1, T2, T3, etc.).
Terminal designations at PLCs where the field conductor connects to field
terminal blocks for a PLC input or output shall be the PLC address (Note: the
following PLC I/O numbering scheme is typical for Allen-Bradley, the numbering
scheme should be modified to match that of the actual PLC manufacturer used
for the project):
Discrete Point: W:X:Y/Z or Analog Point: W:X:Y.Z
Where:
W = I for input, O for output
X =
Terminal designations at PLCs where the conductor does not connect to a PLC
input point or output
C0010). For common power after a fuse or neutrals after a switch, the
C0010A).
3.Case 1: Vendor control panel (CP) to Programmable Logic Controller (PLC):
PLUMMER ASSOCIATES, INC.26 05 53-PAGE 2OF 9BID SET
0537-038-01IDENTIFICATION FOR ELECTRICAL SYSTEMSJANUARY 2023
Field wire number/label: A-B/C-D
A = Vendor control panel number without hyphen (CP#)
terminal number)
C = Programmable Logic Controller number without hyphen (PLC#)
D = Either the PLC address if the field terminal is connected directly to a
connected directly to a PLC I/O point (C0010)
Examples:
CP#-10/PLC#-I:1:01/01
CP#-10/PLC#-O:1:10/07
CP#-10/PLC#-C0100
4.Case 2: Field instrument to Programmable Logic Controller (PLC):
Field wire number/label: E-F/C-D
C = Programmable Logic Controller number without hyphen (PLC#)
D = Either the PLC address if the field terminal is connected directly to a
PLC
connected directly to a PLC I/O point (C0010)
E = Field mounted instrument tag and loop numbers without hyphen
(EDV#)
umber within instrument. Use both
terminal numbers for analog points separated by a comma
Examples:
TIT#-2,3/PLC#-I:1:01.1
TSH#-1/PLC#-I:2:01/00
5.Case 3: Motor control center (MCC) to Programmable Logic Controller (PLC):
Field wire number/label: G-B/C-D
B
C = Programmable Logic Controller without hyphen (PLC#)
D = Either the PLC address if the field terminal is connected directly to a
PLC input or output
connected directly to a PLC I/O point (C0010)
G = Actual starter designation in the motor control center without hyphen
(MMS#)
Examples:
MMS#-10/PLC#-I:1:01/01
MMS#-10/PLC#-O:1:10/07
MMS#-10/PLC#-C0100
6.Case 4: Motor control center (MCC) to vendor control panel (CP):
Field wire number/label: G-B/A-B
A = Vendor control panel number without hyphen (CP#)
B = Terminal number within motor control center or vendor control panel
andard terminal number)
G = Actual starter designation in the motor control center without hyphen
(MMS#)
Example:
MMS#-X2/CP#-10
7.Case 5: Motor leads to a motor control center (MCC):
Field wire number/label: H-I/G-B
PLUMMER ASSOCIATES, INC.26 05 53-PAGE 3OF 9BID SET
0537-038-01IDENTIFICATION FOR ELECTRICAL SYSTEMSJANUARY 2023
B = Terminal number within motor
terminal number)
G = Actual starter designation in the motor control center without hyphen
(MMS#)
H = Equipment tag and loop number without hyphen (PMP#)
I =e.g. T1, T2, T3,
etc.)
Example:
PMP-#-T3/MMS#-T3
8.Case 6: Remote or separately mounted starter or variable frequency drive (VFD) to
Programmable Logic Controller (PLC):
Field wire number/label: J-B/C-D
B = Terminal number within starter or variable frequency drive
C = Programmable Logic Controller number without hyphen (CP#)
D = Either the PLC address if the field terminal is connected directly to a PLC
fix if not connected
directly to a PLC I/O point (C0010)
J = Starter or variable frequency drive tag and loop number without hyphen
(MMS#)
Examples:
MMS#-10/PLC#-I:1:01/01
MMS#-10/PLC#-O:2:10/07
MMS#-10/PLC#-C0010
9.Identify all spare conductors as required
Example:S MMS#-10/PLC#-C011
2.2RACEWAY IDENTIFICATION MATERIALS
A.Comply with ANSIA13.1 for minimum size of letters for legend and for minimum length of
color field for each raceway and cable size.
B.Color for Printed Legend:
1.Power Circuits: Black letters on an orange field.
2.Legend: Indicate system or service and voltage, if applicable.
C.Self-Adhesive Vinyl Labels: Preprinted, flexible label laminated with a clear, weather-and
chemical-resistant coating and matching wraparound adhesive tape for securing ends of
legend label.
D.Snap-Around Labels: Slit, pretension, flexible, preprinted, color-coded acrylic sleeves, with
diameter sized to suit diameter of raceway or cable it identifies and to stay in place by
gripping action.
E.Snap-Around, Color-Coding Bands: Slit, pretension, flexible, solid-colored acrylic sleeves,
2inches long, with diameter sized to suit diameter of raceway or cable it identifies and to
stay in place by gripping action.
F.Self-Adhesive Vinyl Tape: Colored, heavy duty, waterproof, fade resistant; 2inches wide;
compounded for outdoor use.
2.3CONDUCTOR AND COMMUNICATION-AND CONTROL-CABLE IDENTIFICATION MATERIALS
A.All markings to labels, schedules, tags on nameplates shall be machine printed only. Hand
printing is prohibited. Circuits shall be tagged at terminations (both ends), in pull boxes,
cabinets and enclosures as follows;
1.Tags relying on adhesives or taps-on markers are not acceptable.
PLUMMER ASSOCIATES, INC.26 05 53-PAGE 4OF 9BID SET
0537-038-01IDENTIFICATION FOR ELECTRICAL SYSTEMSJANUARY 2023
2.!Hand written tags are not acceptable.
3.!Provide conductor tags for conductors No. 10 AWG and below with legible permanent
sleeve of yellow or white PVC with machine printed black marking, Raychem TMS
sleeves or approved equal.
4.!Provide tags for cables and for conductors No. 8 AWG and larger consisting of
permanent nylon marker plates with legible designations hat tamped on the plate.
Attach these marker plates to conductors and calves with stainless steel wire wraps.
Tags shall be Raychem TMS-CM cable markers or approved equal.
5.!Tags shall be imprinted with panelboard and panelboard position number (e.g. LA3-
23) for conductors fed from panelboards. Other conductors shall have tags imprinted
with the MCC which feeds the conductors (e.g. MCC 1).
6.!Switch-legs shall the designation descried above their tags, plus an "S" suffix.
Travelers shall have the designation described able on their taps, plus a "T" suffix.
7.!Where more than one neutral is present with a group of conductors, a tag shall be
applied to each neutral indicating which phase conductors are served by each neutral
(e.g. HA-2, 4, 6).
B.!Color-Coding Conductor Tape: Colored, self-adhesive vinyl tape not less than 3 mils thick by
1-2 inches wide.
2.4!WARNING LABELS AND SIGNS
A.!Comply with NFPA 70 and 29 CFR 1910.145.
B.!Self-Adhesive Warning Labels: Factory printed, multicolor, pressure-sensitive adhesive
labels, configured for display on front cover, door, or other access to equipment, unless
otherwise indicated.
C.!Baked-Enamel Warning Signs: Preprinted aluminum signs, punched or drilled for fasteners,
with colors, legend, and size required for application. 1/4-inch grommets in corners for
mounting. Nominal size, 7x10 inches.
D.!Metal-Backed, Butyrate Warning Signs: Weather-resistant, non-fading, preprinted, cellulose-
acetate butyrate signs with 0.0396-inch galvanized-steel backing; and with colors, legend,
and size required for application. 1/4-inch grommets in corners for mounting. Nominal size,
10x14 inches.
E.!Warning label and sign shall include, but are not limited to, the following legends:
1.!Multiple Power Source Warning: "DANGER - ELECTRICAL SHOCK HAZARD -
EQUIPMENT HAS MULTIPLE POWER SOURCES."
2.!Workspace Clearance Warning: "WARNING - OSHA REGULATION - AREA IN FRONT
OF ELECTRICAL EQUIPMENT MUST BE KEPT CLEAR FOR 36 INCHES."
2.5!INSTRUCTION SIGNS
A.!Engraved, laminated acrylic or melamine plastic, minimum 1/16-inch thick for signs up to
20 square inches and 1/8-inch thick for larger sizes.
1.!Engraved legend with Insert colors.
2.!Punched or drilled for mechanical fasteners.
3.!Framed with mitered acrylic molding and arranged for attachment at applicable
equipment.
2.6!EQUIPMENT IDENTIFICATION LABELS
A.!Engraved, Laminated Acrylic or Melamine Label: Punched or drilled for screw mounting.
White letters on a dark-gray background. Minimum letter height shall be 3/8 inch.
B.!Stenciled Legend: In non-fading, waterproof, black ink or paint. Minimum letter height shall
be 1 inch.
PLUMMER ASSOCIATES, INC. 26 05 53 - PAGE 5 OF 9 BID SET
0537-038-01 IDENTIFICATION FOR ELECTRICAL SYSTEMS JANUARY 2023
2.7!MISCELLANEOUS IDENTIFICATION PRODUCTS
A.!Cable Ties: Fungus-inert, self-extinguishing, 1-piece, self-locking, Type 6/6 nylon cable ties.
1.!Minimum Width: 3/16 inch.
2.!Tensile Strength: 50 lb., minimum.
3.!Temperature Range: Minus 40 to plus 185°F.
4.!Color: Black, except where used for color-coding.
B.!Paint: Paint materials and application requirements are specified in Division 9 painting
Sections.
C.!Fasteners for Labels and Signs: Self-tapping, stainless-steel screws or stainless-steel
machine screws with nuts and flat and lock washers.
2.8!UNDERGROUND-LINE WARNING TAPE
A.!Tape:
1.!Acid- and alkali-resistant polyethylene film warning tape manufactured for marking
and identifying underground utilities, a minimum of 6 inches wide and 4 mils thick,
continuously inscribed with a description of the utility, with metallic core encased in a
protective jacket for corrosion protection, detectable by metal detector when tape is
buried up to 30 inches deep. Tape shall be red in color for electrical, orange in color
for communication. Printed legend shall indicate type of underground line
B.!Color and Printing:
1.!Comply with ANSI Z535.1 through ANSI Z535.5.
2.!Inscriptions for Red-Colored Tapes: "ELECTRIC LINES"
PART 3 - EXECUTION
3.1!APPLICATION
A.!Raceways and Duct Banks More Than 600 V Concealed within Buildings: 4-inch wide black
stripes on 10-inch centers over orange background that extends full length of raceway or
duct and is 12 inches wide. Stencil legend "DANGER CONCEALED HIGH VOLTAGE WIRING"
with 3-inch high black letters on 20-inch centers. Stop stripes at legends. Apply to the
following finished surfaces:
1.!Floor surface directly above conduits running beneath and within 12 inches of a floor
that is in contact with earth or is framed above unexcavated space.
2.!Wall surfaces directly external to raceways concealed within wall.
3.!Accessible surfaces of concrete envelope around raceways in vertical shafts, exposed
in the building, or concealed above suspended ceilings.
B.!Accessible Raceways and Metal-Clad Cables More Than 600 V: Identify with "DANGER-HIGH
VOLTAGE" in black letters at least 2 inches high, with self-adhesive vinyl labels. Repeat
legend at 10-foot maximum intervals.
C.!Accessible Raceways and Metal-Clad Cables, 600 V or Less, for Service, Feeder, and Branch
Circuits: Identify with orange self-adhesive vinyl label.
D.!Power-Circuit Conductor Identification: For primary and secondary conductors No. 1/0 AWG
and larger in vaults, pull and junction boxes, manholes, and handholes use metal tags.
Identify source and circuit number of each set of conductors. For single conductor cables,
identify phase in addition to the above.
E.!Branch-Circuit Conductor Identification: Where there are conductors for more than three
branch circuits in same junction or pull box, use metal tags. Identify each ungrounded
conductor according to source and circuit number.
PLUMMER ASSOCIATES, INC. 26 05 53 - PAGE 6 OF 9 BID SET
0537-038-01 IDENTIFICATION FOR ELECTRICAL SYSTEMS JANUARY 2023
F.Conductors to Be Extended in the Future: Attach write-on tags to conductors and list source
and circuit number.
G.Auxiliary Electrical Systems Conductor Identification: Identify field-installed alarm, control,
signal, sound, intercommunications, voice, and data connections.
1.Identify conductors, cables, and terminals in enclosures and at junctions, terminals,
and pull points. Identify by system and circuit designation.
2.Use system of marker tape designations that is uniform and consistent with system
used by manufacturer for factory-installed connections.
3.Coordinate identification with Project Drawings, manufacturer's wiring diagrams, and
Operation and Maintenance Manual.
H.Locations of Underground Lines: Identify with underground-line warning tape for power,
lighting, communication, and control wiring and optical fiber cable.
I.Warning Labels for Indoor Cabinets, Boxes, and Enclosures for Power and Lighting: Comply
with 29CFR1910.145 and apply baked-enamel warning signs. Identify system voltage with
black letters on an orange background. Apply to exterior of door, cover, or other access.
1.Equipment with Multiple Power or Control Sources: Apply to door or cover of
equipment including, but not limited to, the following:
Power transfer switches.
Controls with external control power connections.
2.Equipment Requiring Workspace Clearance According to NFPA70: Unless otherwise
indicated,apply to door or cover of equipment but not on flush panelboards and
similar equipment in finished spaces.
J.Instruction Signs:
1.Operating Instructions: Install instruction signs to facilitate proper operation and
maintenance of electrical systems and itemsto which they connect. Install instruction
signs with approved legend where instructions are needed for system or equipment
operation.
2.Emergency Operating Instructions: Install instruction signs with white legend on a
red background with minimum 3/8-inchhigh letters for emergency instructions at
equipment used for power transfer.
K.Equipment Identification Labels: On each unit of equipment, install unique designation label
that is consistent with wiring diagrams, schedules, and Operation and Maintenance Manual.
Apply labels to disconnect switches and protection equipment, central or master units,
control panels, control stations, terminal cabinets, and racks of each system. Systems
include power, lighting, control, communication, signal, monitoring, and alarm systems
unless equipment is provided with its own identification.
L.Labeling Instructions:
1.Indoor Equipment: Engraved, laminated acrylic or melamine label. Unless otherwise
indicated, provide a single line of text with 1/2-inch high letters on 1-1/2-inch high
label; where 2 lines of text are required, use labels 2inches high.
2.Outdoor Equipment: Stenciled legend 4 inches high.
3.Elevated Components: Increase sizes of labels and letters to those appropriate for
viewing from the floor.
4.Equipment to Be Labeled:
Panelboards, electrical cabinets, and enclosures.
Access doors and panels for concealed electrical items.
Electrical switchgear and switchboards.
Transformers.
Electrical substations.
Emergency system boxes and enclosures.
PLUMMER ASSOCIATES, INC.26 05 53-PAGE 7OF 9BID SET
0537-038-01IDENTIFICATION FOR ELECTRICAL SYSTEMSJANUARY 2023
Motor-control centers.
Disconnect switches.
Enclosed circuit breakers.
Motor starters.
Push-button stations.
Power transfer equipment.
Contactors.
Remote-controlled switches, dimmer modules, and control devices.
Battery inverter units.
Battery racks.
Power-generating units.
Voice and data cable terminal equipment.
Master clock and program equipment.
Intercommunication and call system master and staff stations.
Television/audio components, racks, and controls.
Fire-alarm control panel and annunciator.
Security and intrusion-detection control stations, control panels, terminal
cabinets, and racks.
Monitoring and control equipment.
Uninterruptible power supply equipment.
Terminals, racks, and patch panels for voice and data communication and for
signal and control functions.
3.2INSTALLATION
A.Verify identity of each item before installing identification products.
B.Location: Install identification materials and devices at locations for most convenient
viewing without interference with operation and maintenance of equipment.
C.Apply identification devices to surfaces that require finish after completing finish work.
D.Self-Adhesive Identification Products: Clean surfaces before application, using materials and
methods recommended by manufacturer of identification device.
E.Attach non-adhesive signs and plastic labels with screws and auxiliary hardware appropriate
to the location and substrate.
F.System Identification Color Banding for Raceways and Cables: Each color band shall
completely encircle cable or conduit. Place adjacent bands of two-color markings in contact,
side by side. Locate bands at changes in direction, at penetrations of walls and floors, at 50-
foot maximum intervals in straight runs, and at 25-foot maximum intervals in congested
areas.
G.Color-Coding for Phaseand Voltage Level Identification, 600V and Less: Use the colors
listed below for ungrounded service, feeder, and branch-circuit conductors.
1.Color shall be factory applied or, for sizes larger than No.10AWG if authorities
having jurisdiction permit, field applied.
Colors for 208/120V Circuits:
PhaseA: Black.
PhaseB: Red.
PhaseC: Blue.
Colors for 480/277V Circuits:
PhaseA: Brown.
PhaseB: Orange.
PhaseC: Yellow.
2.Field-Applied, Color-Coding Conductor Tape: Apply in half-lapped turns for a
minimum distance of 6 inches from terminal points and in boxes where splices or taps
PLUMMER ASSOCIATES, INC.26 05 53-PAGE 8OF 9BID SET
0537-038-01IDENTIFICATION FOR ELECTRICAL SYSTEMSJANUARY 2023
are made. Apply last 2 turns of tape with no tension to prevent possible unwinding.
Locate bands to avoid obscuring factory cable markings.
H.!Aluminum Wraparound Marker Labels and Metal Tags: Secure tight to surface of conductor
or cable at a location with high visibility and accessibility.
I.!Painted Identification: Prepare surface and apply paint according to Division 9 painting
Sections.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 05 53 - PAGE 9 OF 9 BID SET
0537-038-01 IDENTIFICATION FOR ELECTRICAL SYSTEMS JANUARY 2023
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PART 1 - GENERAL
1.1!SUMMARY
A.!The CONTRACTOR shall furnish and install single-phase and three-phase general purpose
individually mounted mini-power centers of the two-winding type, self-cooled, as specified
herein and as shown on the contract drawings.
1.2!REFERENCES
A.!The mini-power center and all components shall be designed, manufactured and tested in
accordance with the latest applicable standards of UL, ANSI and NEMA.
1.3!ADMINISTRATIVE REQUIREMENTS - NOT USED
1.4!SUBMITTALS
A.!For review/approval: The following information shall be submitted to the ENGINEER:
1.!Dimension drawing weights
2.!Transformer ratings including:
a.!kiloVoltAmp
b.!Primary and secondary voltage
c.!Taps
d.!Primary and secondary continuous current
e.!Insulation class and temperature rise
f.!Sound level
3.!Component ratings including:
a.!Voltage
b.!Continuous current
c.!Interrupting ratings
4.!Cable terminal sizes
5.!Product data sheets.
B.!For construction. The following information shall be submitted for record purposes:
1.!Final (as-built) drawings and information for items listed in Paragraph 1.04, and shall
incorporate all changes made during the manufacturing process
2.!Connection diagrams
3.!Installation information
1.5!QUALITY ASSURANCE
A.!The manufacturer of the assembly shall be the manufacturer of the secondary distribution
equipment.
B.!For the equipment specified herein, the manufacturer shall be ISO 9001 or 9002 certified.
PLUMMER ASSOCIATES, INC. 26 27 00.11 - PAGE 1 OF 4 90% REVIEW SET
0537-038-01 MINI-POWER CENTERS APRIL 2022
C.!The manufacturer of this equipment shall have produced similar electrical equipment for a
minimum period of 5 years.
1.6!DELIVERY, STORAGE AND HANDLING
A.!
copy of these instructions shall be included with the equipment at time of shipment.
1.7!SITE CONDITIONS - NOT USED
1.8!WARRANTY - NOT USED
1.9!REGULATORY REQUIREMENTS
A.!The assembly and all components shall be UL listed.
1.10!OPERATION AND MAINTENANCE MANUALS
A.!Equipment operation and maintenance manuals shall be provided with each assembly
shipped and shall include instruction leaflets and instruction bulletins for the complete
assembly and for each major component.
PART 2 - PRODUCTS
2.1!MANUFACTURERS
A.!Manufacturer: Subject to compliance with the requirements of this Section, provide
products by one of the following:
1.!Eaton Corporation; Cutler-Hammer Products.
2.!General Electric Company; GE Industrial Systems.
3.!Square D; Schneider Electric.
4.!Siemens
2.2!RATINGS
A.!kVA and voltage ratings shall be as shown on the drawings.
B.!Units shall be designed for continuous operation at rated kVA, for 24 hours a day, 365 days a
year operation, with normal life expectancy as defined in ANSI C57.96.
C.!Transformer sound levels shall not exceed the following ANSI and NEMA levels for self-
cooled ratings:
1.!Up to 9 kVA 40 dB
2.!10-30 kVA 45 dB
2.3!CONSTRUCTION
A.!Each mini-power center shall include a primary main breaker, an encapsulated dry-type
transformer and a panelboard with secondary main breaker.
B.!Primary main, secondary main and feeder breakers shall be enclosed with a padlockable
hinged door.
C.!Mini-power centers shall be suitable for service entrance application and labeled as such.
PLUMMER ASSOCIATES, INC. 26 27 00.11 - PAGE 2 OF 4 90% REVIEW SET
0537-038-01 MINI-POWER CENTERS APRIL 2022
D.!Insulation Systems
1.!Transformers shall be insulated with a 180ºC insulation system and rated at 115ºC
temperature rise
2.!Required performance shall be obtained without exceeding the above-indicated
temperature rise in a 40ºC maximum ambient, with a 30ºC average over 24 hours
3.!All insulation materials shall be flame-retardant and shall not support combustion as
defined in ASTM Standard Test Method D635
E.!Core and Coil Assemblies
1.!Transformer core shall be constructed with high-grade, non-aging, silicon steel with
high magnetic permeability, and low hysteresis and eddy current losses. Maximum
magnetic flux densities shall be substantially below the saturation point. The
transformer core volume shall allow efficient transformer operation at 10% above the
nominal tap voltage. The core laminations shall be tightly clamped and compressed.
Coils shall be wound of copper with continuous wound construction.
2.!The core and coil assembly shall be completely encapsulated in a proportioned
mixture of resin and aggregate to provide a moisture proof, shock-resistant seal. The
core and coil encapsulation system shall minimize the sound level.
3.!The core of the transformer shall be grounded to the enclosure
4.!Provide two 5% FCBN taps
2.4!BUS
A.!Secondary bus shall be copper.
2.5!WIRING/TERMINATIONS
A.!All interconnecting wiring between the primary breaker and transformer, secondary main
breaker and transformer and distribution section shall be factory installed.
B.!All transformers shall be equipped with a wiring compartment suitable for conduit entry and
large enough to allow convenient wiring.
2.6!MAIN DEVICES
A.!Each mini-power center shall include a primary main breaker with an interrupting rating of
14 kA at 277/480 V; and a secondary main breaker with an interrupting rating of 10 kA at
120/240 V and a panelboard.
2.7!FEEDER DEVICES
A.!The secondary distribution section shall accommodate one-inch plug-in breakers with 10 kA
interrupting capacity.
2.8!ENCLOSURE
A.!The enclosure shall be made of heavy-gauge steel and the maximum temperature of the
enclosure shall not exceed 90ºC.
B.!The enclosure shall be totally enclosed, nonventilated, NEMA 4X SST, with latching handle.
PLUMMER ASSOCIATES, INC. 26 27 00.11 - PAGE 3 OF 4 90% REVIEW SET
0537-038-01 MINI-POWER CENTERS APRIL 2022
PART 3 - EXECUTION
3.1!FACTORY TESTING
A.!The following standard factory tests shall be performed on the equipment provided under
this section. All tests shall be in accordance with the latest version of ANSI and NEMA.
1.!Ratio tests at the rated voltage connection and at all tap connections
2.!Polarity and phase-relation tests on the rated voltage connection
3.!Applied potential tests
4.!Induced potential test
5.!No-load and excitation current at rated voltage on the rated voltage connection
3.2!INSTALLATION
A.!
the contract drawings.
3.3!FIELD ADJUSTMENTS
A.!Adjust taps to deliver appropriate secondary voltage.
3.4!FIELD TESTING
A.!Measure primary and secondary voltages for proper tap settings.
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0537-038-01 MINI-POWER CENTERS APRIL 2022
SECTION 26 27 26
WIRING DEVICES
PART 1 - GENERAL
1.1!SUMMARY
A.!This Section includes the following:
1.!Receptacles (Hospital-grade), receptacles with integral GFCI, and associated device
plates.
2.!Snap switches and wall-box dimmers.
3.!Wall-switch and exterior occupancy sensors.
4.!Communications outlets.
1.2!DEFINITIONS
A.!EMI: Electromagnetic interference.
B.!GFCI: Ground-fault circuit interrupter.
C.!Pigtail: Short lead used to connect a device to a branch-circuit conductor.
D.!RFI: Radio-frequency interference.
E.!TVSS: Transient voltage surge suppressor.
F.!UTP: Unshielded twisted pair.
1.3!SUBMITTALS
A.!Product Data: For each type of product indicated.
B.!Shop Drawings: List of legends and description of materials and process used for
premarking wall plates.
C.!Field quality-control test reports.
D.!Operation and Maintenance Data: For wiring devices to include in all manufacturers'
packing label warnings and instruction manuals that include labeling conditions.
1.4!QUALITY ASSURANCE
A.!Source Limitations: Obtain each type of wiring device and associated wall plate through one
source from a single manufacturer. Insofar as they are available, obtain all wiring devices
and associated wall plates from a single manufacturer and one source.
B.!Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,
Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for
intended use.
C.!Comply with NFPA 70.
PART 2 - PRODUCTS
2.1!MANUFACTURERS
A.!Available Manufacturers: Subject to compliance with requirements, manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.!Cooper Wiring Devices; a division of Cooper Industries, Inc. (Cooper).
2.!Hubbell Incorporated; Wiring Device-Kellems (Hubbell).
3.!Leviton Mfg. Company Inc. (Leviton).
4.!Pass & Seymour/Legrand; Wiring Devices & Accessories (Pass & Seymour).
PLUMMER ASSOCIATES, INC. 26 27 26 - PAGE 1 OF 4 BID SET
0537-038-01 WIRING DEVICES JANUARY 2023
2.2!STRAIGHT BLADE RECEPTACLES
A.!Extra heavy-duty industrial grade specification grade, 125 V, 20 A: Comply with
NEMA WD 1, NEMA WD 6 configuration 5-20R, and UL 498 Supplement SD.
2.3!GFCI RECEPTACLES
A.!Extra heavy-duty industrial grade specification grade, self-text, straight blade, 125 V, 20 A,
non-feed-through type. Comply with NEMA WD 1, NEMA WD 6, UL 498, and UL 943,
Class A, and include LED status indicator light which to provide visual indication of the status
of the GFCI protection. (Green-Normal, Red-Alert, No indication-no power).
2.4!HAZARDOUS (CLASSIFIED) LOCATION RECEPTACLES
A.!Wiring Devices for Hazardous (Classified) Locations: Comply with NEMA FB 11 and UL 1010.
2.5!TOGGLE SWITCHES
A.!Extra heavy-duty industrial specification grade, comply with NEMA WD 1 and UL 20,
120/277 V, 20 A, ac toggle ac quirt switch.
2.6!WALL-BOX DIMMERS
A.!Modular, full-wave, solid-state units with integral, quiet on-off switches, with audible
frequency, and with EMI/RFI suppression filters, compatible with dimmer ballasts/LEDs.
Continuously adjustable slider with single-pole or 3-way switching. Comply with UL 1472.
2.7!OCCUPANCY SENSORS
A.!Passive-infrared type single pole wall switch, which provides 2,100 square feet of coverage,
manual adjustable time delay off up to up to 20 min. and manual override.
2.8!COMMUNICATIONS/DATA OUTLETS
A.!System shall be configurable snap port modules that support various data connectors.
Single-gang plate shall fit stand box and shall be angle single-gang 4-point wall plate. All
unused ports shall have blank ports. Wall plate shall be colored in finished areas and
stainless steel in unfinished areas.
1.!Telephone Outlet: Single RJ-45 jack for terminating 100 four-pair UTP;
TIA/EIA-568-B.1; complying with Category 5e. Comply with UL 1863.
2.!Ethernet Outlet: Single RJ-45 jack for terminating 100 -pair UTP;
TIA/EIA-568-B.1; complying with Category 5e. Comply with UL 1863.
2.9!WALL PLATES
A.!Single and combination types to match corresponding wiring devices.
1.!Material for Finished Spaces: Steel with white baked enamel, suitable for field
painting. Plate-securing screws, metal with head color to match plate finish.
2.!Material for Unfinished Spaces: Vandal resistance, stainless steel 14 gauge. Plate-
securing screws, vandal resistance stainless steel.
3.!Material for Damp Locations: Cast aluminum with spring-loaded lift cover, and listed
and labeled for use in "wet locations."
B.!Wet-Location, Weatherproof Cover Plates: NEMA 250, complying with type 3R weather-
resistant, die-cast aluminum with lockable cover.
C.!Wet-Location, While in Use Covers: Comply with NEC for "Extra Duty" application hoods.
Polycarbonate material, UL listed, with safety lock.
PLUMMER ASSOCIATES, INC. 26 27 26 - PAGE 2 OF 4 BID SET
0537-038-01 WIRING DEVICES JANUARY 2023
2.10FINISHES
A.Color:
1.Wiring Devices Connected to Normal Power System: As selected by ENGINEER,
unless otherwise indicated or required by NFPA70 or device listing.
2.Wiring Devices Connected to Emergency Power System: Red.
3.Isolated-Ground Receptacles: Orange.
PART 3 -EXECUTION
3.1INSTALLATION
A.Comply with NECA1, including the mounting heights listed in that standard, unless
otherwise noted.
B.Coordination with Other Trades:
1.Take steps to ensure that devices and their boxes are protected. Do not place wall
finish materials over device boxesand do not cut holes for boxes with routers that are
guided by riding against outside of the boxes.
2.Keep outlet boxes free of plaster, drywall joint compound, mortar, cement, concrete,
dust, paint, and other material that may contaminate the raceway system,
conductors, and cables.
3.Install device boxes in brick or block walls so that the cover plate does not cross a
joint unless the joint is troweled flush with the face of the wall.
4.Install wiring devices after all wall preparation, including painting, is complete.
C.Conductors:
1.Do not strip insulation from conductors until just before they are spliced or terminated
on devices.
2.Strip insulation evenly around the conductor using tools designed for the purpose.
Avoid scoring or nicking of solid wire or cutting strands from stranded wire.
3.The length of free conductors at outlets for devices shall meet provisions of NFPA70,
Article 300, without pigtails.
4.Existing Conductors:
Cut back and pigtail, or replace all damaged conductors.
Straighten conductors that remain and remove corrosion and foreign matter.
Pigtailing existing conductors is permitted provided the outlet box is large
enough.
D.Device Installation:
1.Replace all devices that have been in temporary use during construction or that show
signs that they were installed before building finishing operations were complete.
2.Keep each wiring device in its package or otherwise protected until it is time to
connect conductors.
3.Do not remove surface protection, such as plastic film and smudge covers, until the
last possible moment.
4.Connect devices to branch circuits using pigtails that are not less than 6inches in
length.
5.When there is a choice, use side wiring with binding-head screw terminals. Wrap solid
conductor tightly clockwise, 2/3-3/4 of the way around the terminal screw.
6.Use a torque screwdriver when a torque is recommended or required by the
manufacturer.
7.When conductors larger than No.12AWG are installed on 15-A or 20-A circuits, splice
No.12AWG pigtails for device connections.
PLUMMER ASSOCIATES, INC.26 27 26-PAGE 3OF 4BID SET
0537-038-01WIRING DEVICESJANUARY 2023
8.!Tighten unused terminal screws on the device.
9.!When mounting into metal boxes, remove the fiber or plastic washers used to hold
device mounting screws in yokes, allowing metal-to-metal contact.
E.!Receptacle Orientation:
1.!Install ground pin of vertically mounted receptacles up, and on horizontally mounted
receptacles to the right.
F.!Device Plates: Do not use oversized or extra-deep plates. Repair wall finishes and remount
outlet boxes when standard device plates do not fit flush or do not cover rough wall
opening.
G.!Dimmers:
1.!Install dimmers within terms of their listing.
2.!Verify that dimmers used for fan speed control are listed for that application.
3.!Install unshared neutral conductors on line and load side of dimmers according to
manufacturers' device listing conditions in the written instructions.
H.!Arrangement of Devices: Unless otherwise indicated, mount flush, with long dimension
vertical and with grounding terminal of receptacles on top. Group adjacent switches under
single, multigang wall plates.
I.!Adjust locations of floor service outlets and service poles to suit arrangement of partitions
and furnishings.
3.2!IDENTIFICATION
A.!Comply with Division 16 Section "Electrical Identification."
1.!Receptacles: Identify panelboard and circuit number from which served. Use hot,
stamped or engraved machine printing with white-filled lettering on face of plate, and
durable wire markers or tags inside outlet boxes.
3.3!FIELD QUALITY CONTROL
A.!Perform tests and inspections and prepare test reports.
1.!In healthcare facilities, prepare reports that comply with recommendations in
NFPA 99.
2.!Test Instruments: Use instruments that comply with UL 1436.
3.!Test Instrument for Convenience Receptacles: Digital wiring analyzer with digital
readout or illuminated LED indicators of measurement.
B.!Tests for Convenience Receptacles:
1.!Line Voltage: Acceptable range is 105-132 V.
2.!Percent Voltage Drop under 15-A Load: A value of 6% or higher is not acceptable.
3.!Ground Impedance: Values of up to 2
4.!GFCI Trip: Test for tripping values specified in UL 1436 and UL 943.
5.!Using the test plug, verify that the device and its outlet box are securely mounted.
6.!The tests shall be diagnostic, indicating damaged conductors, high resistance at the
circuit breaker, poor connections, inadequate fault current path, defective devices, or
similar problems. Correct circuit conditions, remove malfunctioning units and replace
with new ones, and retest as specified above.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 27 26 - PAGE 4 OF 4 BID SET
0537-038-01 WIRING DEVICES JANUARY 2023
SECTION 26 27 29
SWITCH RATED PLUGS AND RECEPTACLES
PART 1 - GENERAL
1.1!SCOPE OF WORK
A.!Furnish all labor, materials, equipment and install wiring devices as shown on the Drawings
and as specified herein.
B.!Provide all interconnecting conduit and branch circuit wiring for receptacle circuits in
accordance with the NEC.
1.2!RELATED WORK
A.!Section 26 05 33 Raceways and Boxes for Electrical Systems.
1.3!SUBMITTALS
A.!Submittals shall be in accordance with Section 26 00 00.
1.4!REFERENCE STANDARDS
A.!Wiring devices shall comply with the requirements of the National Electric Code (NEC) and
shall be Underwriters Laboratories (UL) labeled.
PART 2 - PRODUCTS
2.1!MATERIALS
2.2!SWITCH RATED PLUGS AND RECEPTACLES
A.!Plugs and receptacles must be listed to UL 2682 'Switch Rated Plugs and Receptacles.'
(Alternate for Canada: Plugs and receptacles must be CSA listed to UL 2682 'Switch Rated
Plugs and Receptacles').
B.!Plugs and receptacles must have constant pressure butt-contacts with solid silver-nickel tips.
Pin and sleeve contacts are not permitted.
C.!Receptacles must have dead front construction: live parts must be inaccessible to thin tool
or wire.
D.!Plugs and receptacles must be able to close at least once on a conditional short-circuit
current of 65,000A. (Short circuit testing should be performed with RK1 current limiting
fuses sized at 400% of the highest full load motor ampacity associated with the device).
E.!Plugs and receptacles must incorporate an integral switching mechanism to ensure the load
is broken before the plug is removed from the receptacle.
F.!Plug and receptacle wire terminals must be spring-assisted to prevent loosening due to
conductor yielding, shocks, vibrations or thermal cycling.
G.!The minimum environmental rating of plugs and receptacles must be Type 3R (DS Series),
Type 4X and IP66/IP67/IP69K (DSN Series), or IP67 (DB Series).
H.!Ingress protection must be achieved automatically when the plug is fully inserted into the
receptacles, without additional manual operation (except DB Series).
I.!Plugs and receptacles must have a system of different keying positions in order to
discriminate between circuits or incompatible operating voltages or frequencies.
J.!Plugs and receptacles installed outdoor must be able to withstand UV radiation.
K.!Plugs and receptacles shall be MELTRIC Switch-Rated Series or equal.
PLUMMER ASSOCIATES, INC. 26 27 29 - PAGE 1 OF 2 BID SET
0537-038-01 SWITCH RATED PLUGS AND RECEPTACLES JANUARY 2023
2.3!HAZARDOUS DUTY RATED PLUGS AND RECEPTACLES
A.!Plugs and receptacles shall be UL or CSA rated for Class I Division 2 Group A, B, C, D and
Class II Division 2 Group E, F, G environments.
B.!Plugs and receptacles shall be rated to ATEX II 2 G/D DUST T85 EEx ed IIC T6.
C.!The minimum environmental rating of plugs and receptacles must be IP 66+67. Ingress
Protection must be achieved automatically when the plug is fully inserted into the
receptacles, without any additional manual operation.
D.!Receptacles shall have a dead front, live parts must be inaccessible to a thin tool or wire.
E.!Plugs and receptacles shall have constant pressure butt-contacts with solid silver-nickel
contact tips. Pin and sleeve contacts are not permitted.
F.!Plugs and receptacles shall be able to safely connect and disconnect equipment under full
load in potentially explosive environments.
G.!Hazardous duty rated plugs and receptacles shall be MELTRIC DXN Series or equal.
PART 3 - EXECUTION
3.1!INSTALLATION
A.!Switch and receptacles outlets shall be installed flush with the finished wall surfaces in areas
with stud frame and gypsum board construction, in dry areas with cement block
construction or when raceways are shown as concealed on the Drawings.
B.!Do not install flush mounted devices in areas designated DAMP, WET or WET/CORROSIVE
on the Drawings. Provide surface mounted devices in these areas.
C.!Where individual ground fault interrupter type receptacles are shown on the Drawings
connected to the same circuit, the Contractor shall provide all ground fault interrupter type
receptacles. Use of one ground fault interrupter type receptacle to protect downstream
conventional receptacles is unacceptable.
D.!Provide -In-
designated CORROSIVE on the Drawings.
E.!Convenience outlets shall be 18-in above the floor unless otherwise required or shown on
the Drawings.
F.!Convenience outlets installed in rooms designated as WET or where equipment may be
hosed down shall be mounted minimum 48-in above deck or grade (or as shown on the
Drawings) and shall be weather & tamper resistant, ground fault circuit interrupter type,
-In-erproof cover..
G.!Convenience outlets mounted outdoors shall be mounted minimum 48-in above deck or
grade (or as shown on the Drawings) and shall be weather & tamper resistant, ground fault
-In-roof cover.
H.!Switches and dimmer controls for lighting shall be mounted 48-in above the finished floor
unless otherwise noted or required.
I.!The location of all devices is shown, in general, on the Drawings and may be varied within
reasonable limits so as to avoid any piping or other obstruction without extra cost, subject to
the approval of the Engineer. Coordinate the installation of the devices for piping and
equipment clearance.
END OF SECTION
PLUMMER ASSOCIATES, INC. 26 27 29 - PAGE 2 OF 2 BID SET
0537-038-01 SWITCH RATED PLUGS AND RECEPTACLES JANUARY 2023
SECTION 26 28 16
ENCLOSED SWITCHES AND CIRCUITS BREAKERS
PART 1 - GENERAL
1.1!SUMMARY
A.!Section Includes:
1.!Fusible switches.
2.!Nonfusible switches.
3.!Molded-case circuit breakers (MCCBs).
1.2!SUBMITTALS
A.!Product Data: For each type of enclosed switch, circuit breaker, accessory, and component
indicated. Include dimensioned elevations, sections, weights, and manufacturers' technical
data on features, performance, electrical characteristics, ratings, accessories, and finishes.
1.!Enclosure types and details.
2.!Current and voltage ratings.
3.!Short-circuit current ratings (interrupting and withstand, as appropriate).
B.!Shop Drawings: For enclosed switches and circuit breakers. Include plans, elevations,
sections, details, and attachments to other work.
1.!Wiring Diagrams: For power, signal, and control wiring.
C.!Field quality-control reports.
1.!Test procedures used.
2.!Test results that comply with requirements.
3.!Results of failed tests and corrective action taken to achieve test results that comply
with requirements.
D.!Manufacturer's field service report.
E.!Operation and Maintenance Data: For enclosed switches and circuit breakers to include in
emergency, operation, and maintenance manuals. In addition to items specified in Division 1
Section "Operation and Maintenance Data," include the following:
1.!Manufacturer's written instructions for testing and adjusting enclosed switches and
circuit breakers.
1.3!QUALITY ASSURANCE
A.!Source Limitations: Obtain enclosed switches and circuit breakers, overcurrent protective
devices, components, and accessories, within same product category, from single source
from single manufacturer.
B.!Product Selection for Restricted Space: Drawings indicate maximum dimensions for
enclosed switches and circuit breakers, including clearances between enclosures, and
adjacent surfaces and other items. Comply with indicated maximum dimensions.
C.!Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,
by a qualified testing agency, and marked for intended location and application.
D.!Comply with NFPA 70.
1.4!PROJECT CONDITIONS
A.!Environmental Limitations: Rate equipment for continuous operation under the following
conditions unless otherwise indicated:
PLUMMER ASSOCIATES, INC. 26 28 16 - PAGE 1 OF 4 BID SET
0537-038-01 ENCLOSED SWITCHES AND CIRCUIT BREAKERS JANUARY 2023
1.!Ambient Temperature: Not less than minus 22º F and not exceeding 120º F.
2.!Altitude: Not exceeding 6,600 feet.
1.5!COORDINATION
A.!Coordinate layout and installation of switches, circuit breakers, and components with
equipment served and adjacent surfaces. Maintain required workspace clearances and
required clearances for equipment access doors and panels.
1.6!EXTRA MATERIALS
A.!Furnish extra materials that match products installed and that are packaged with protective
covering for storage and identified with labels describing contents.
1.!Fuses: Equal to 10% of quantity installed for each size and type, but no fewer than
three of each size and type.
2.!Fuse Pullers: Two for each size and type.
PART 2 - PRODUCTS
2.1!FUSIBLE SWITCHES
A.!Manufacturers: Subject to compliance with the requirements of this Section, provide
products by one of the following:
1.!Eaton Corporation; Cutler-Hammer Products.
2.!General Electric Company; GE Industrial Systems.
3.!Square D; Schneider Electric.
B.!Type HD, Heavy Duty, Single Throw, 600 Vac, 1,200 A and Smaller: UL 98 and NEMA KS 1,
horsepower rated, with clips or bolt pads to accommodate specified fuses, lockable handle
with capability to accept 3 padlocks, and interlocked with cover in closed position.
C.!Accessories:
1.!Equipment Ground Kit: Internally mounted and labeled for copper and aluminum
ground conductors.
2.!Neutral Kit: Internally mounted; insulated, capable of being grounded and bonded;
labeled for copper and aluminum neutral conductors.
3.!Lugs: Mechanical type, suitable for number, size, and conductor material.
4.!Service-Rated Switches: Labeled for use as service equipment.
2.2!NONFUSIBLE SWITCHES
A.!Manufacturers: Subject to compliance with the requirements of this Section, provide
products by one of the following:
1.!Eaton Corporation; Cutler-Hammer Products.
2.!General Electric Company; GE Industrial Systems.
3.!Square D; Schneider Electric.
B.!Type HD, Heavy Duty, Single Throw, 600 Vac, 1,200 A and Smaller: UL 98 and NEMA KS 1,
horsepower rated, lockable handle with capability to accept 3 padlocks, and interlocked with
cover in closed position.
C.!Accessories:
1.!Equipment Ground Kit: Internally mounted and labeled for copper and aluminum
ground conductors.
2.!Neutral Kit: Internally mounted; insulated, capable of being grounded and bonded;
labeled for copper and aluminum neutral conductors.
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0537-038-01 ENCLOSED SWITCHES AND CIRCUIT BREAKERS JANUARY 2023
3.!Lugs: Mechanical type, suitable for number, size, and conductor material.
2.3!MOLDED-CASE CIRCUIT BREAKERS
A.!Manufacturers: Subject to compliance with the requirements of this Section, provide
products by one of the following:
1.!Eaton Corporation; Cutler-Hammer Products.
2.!General Electric Company; GE Industrial Systems.
3.!Square D; Schneider Electric.
B.!General Requirements: Comply with UL 489, NEMA AB 1, and NEMA AB 3, with interrupting
capacity to comply with available fault currents.
C.!Thermal-Magnetic Circuit Breakers: Inverse time-current element for low-level overloads
and instantaneous magnetic trip element for short circuits. Adjustable magnetic trip setting
for circuit-breaker frame sizes 250 A and larger.
D.!Features and Accessories:
1.!Standard frame sizes, trip ratings, and number of poles.
2.!Lugs: Mechanical type, suitable for number, size, trip ratings, and conductor material.
2.4!ENCLOSURES
A.!Enclosed Switches and Circuit Breakers: NEMA AB 1, NEMA KS 1, NEMA 250, and UL 50, to
comply with environmental conditions at installed location.
1.!Indoor, Dry and Clean Locations: NEMA 250, NEMA 12.
2.!Outdoor Locations: NEMA 250, NEMA 4X Type 316 Stainless Steel.
3.!Other Wet or Damp, Indoor Locations: NEMA 250, NEMA 4X Type 316 Stainless
Steel.
PART 3 - EXECUTION
3.1!EXAMINATION
A.!Examine elements and surfaces to receive enclosed switches and circuit breakers for
compliance with installation tolerances and other conditions affecting performance of the
Work.
B.!Proceed with installation only after unsatisfactory conditions have been corrected.
3.2!INSTALLATION
A.!Install individual wall-mounted switches and circuit breakers with tops at uniform height
unless otherwise indicated.
B.!Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and
temporary blocking of moving parts from enclosures and components.
C.!Install fuses in fusible devices.
D.!Comply with NECA 1.
3.3!IDENTIFICATION
A.!Comply with requirements in Division 26 Section 26 05 53 "Identification for Electrical
1.!Identify field-installed conductors, interconnecting wiring, and components; provide
warning signs.
2.!Label each enclosure with engraved metal or laminated-plastic nameplate.
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0537-038-01 ENCLOSED SWITCHES AND CIRCUIT BREAKERS JANUARY 2023
3.4FIELD QUALITY CONTROL
A.Acceptance Testing Preparation:
1.Test insulation resistance for each enclosed switch and circuit breaker, component,
connecting supply, feeder, and control circuit.
2.Test continuity of each circuit.
B.Manufacturer's Field Service: Engage a factory-authorized service representative to perform
the following:
1.Inspect switchgear, wiring, components, connections, and equipment installation.
Test and adjust components and equipment.
2.Assist in field testing of equipment,including pretesting and adjusting of automatic
power factor correction units as applicable.
3.Report results in writing.
C.Tests and Inspections:
1.Perform each visual and mechanical inspection and electrical test stated in NETA
Acceptance Testing Specification. Certify compliance with test parameters.
2.Correct malfunctioning units on-site, where possible, and retest to demonstrate
compliance; otherwise, replace with new units and retest.
3.Perform the following infrared scan tests and inspections and prepare reports:
Initial Infrared Scanning: After Substantial Completion, but not more than
60days after Final Acceptance, perform an infrared scan of each enclosed
switch and circuit breaker. Remove front panels so joints and connections are
accessible to portable scanner.
Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of
each enclosed switch and circuit breaker 11months after date of Substantial
Completion.
Instruments and Equipment: Use an infrared scanning device designed to
measure temperature or to detect significant deviations from normal values.
Provide calibration record for device.
4.Test and adjust controls, remote monitoring, and safeties. Replace damaged and
malfunctioning controls and equipment.
D.Enclosed switches and circuit breakers will be considered defective if they do not pass tests
and inspections.
E.Prepare test and inspection report, including a certified report that identifies enclosed
switches and circuit breakers and that describes scanning results. Include notation of
deficiencies detected, remedial action taken and observations after remedial action.
3.5ADJUSTING
A.Adjust moving parts and operable components to function smoothly and lubricate as
recommended by manufacturer.
B.Set field-adjustable circuit-breaker trip ranges.
END OF SECTION
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0537-038-01ENCLOSED SWITCHES AND CIRCUIT BREAKERSJANUARY 2023
SECTION 26 29 03
LOW-VOLTAGE PILOT CONTROL DEVICES
PART 1 - GENERAL
1.1!SUMMARY
A.!Furnish and install all equipment, accessories and materials in accordance with these
specifications and drawings
B.!Electrical control devices for panels, motor controllers, control stations, etc. Section includes
the following;
1.!Pilot Devices
2.!Relays and Timers
3.!Miniature Circuit Breakers
4.!Terminal Blocks and Fuse Blocks
5.!Alarms and Signals
6.!Power Supplies
7.!Signal Conditioners/Isolators
1.2!REFERENCES
A.!Electrical control devices shall be designed, fabricated, and tested in accordance with the
latest revision of the following standards.
1.!National Electrical Manufacturers Association (NEMA):
a.!250, Enclosures for Electrical Equipment (1,000 V Maximum).
b.!ICS-2 Industrial Control and Systems: Controllers, Contactors, and Overload
Relays Rated 600 V
2.!NFPA (National Fire Protection Association):
a.!70 National Electrical Code (NEC)
3.!Underwriters Laboratories (UL):
a.!508, Standard for Safety Industrial Control Equipment.
b.!508A, Standard for Safety Industrial Control Panels.
1.3!ENVIRONMENTAL REQUIREMENTS
A.!The supplier shall confirm specified service conditions during and after installation of
products.
B.!The supplier shall maintain the area free of dirt and dust during and after installation of
products.
1.4!SUBMITTALS
A.!Submittals shall be made in accordance with Submittal Procedures.
B.!Shop drawings (to NEMA ICS 1) shall be submitted to indicate control panel layouts, wiring
connections and diagrams, dimensions and support points.
C.!Product data for each electrical control device specified shall be submitted and included as
part of the system in which the device is specified.
D.!The manufacturer
1.!Receiving, handling and storage instructions.
2.!Instructions for adjusting and resetting devices.
3.!Recommended preventive maintenance procedures.
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0537-038-01 LOW-VOLTAGE PILOT CONTROL DEVICES JANUARY 2023
1.5QUALITY ASSURANCE
A.Supplier of Industrial Control Panels shall build control panel under the provisions of
UL508A.
1.Entire assembly shall be affixed with a UL508A label "Listed Enclosed Instruction
Control Panel" prior to shipment to the jobsite.
PART 2 -PRODUCTS
2.1MANUFACTURERS
A.Manufacturers: Unless listed within the product description, product shall be subject to
compliance with requirements and provided by one of the following:
1.Eaton Corporation; Cutler-Hammer Products.
2.General Electric Company; GE Industrial Systems.
3.Rockwell Automation; Allen-Bradley Co.; Industrial Control Group.
4.Square D; a brand of Schneider Electric.
2.2PILOT DEVICES
A.Push Buttons, Selector Switches and Pilot Lights
1.Push buttons, Type 4/4X/13 corrosion-resistant/watertight/oiltight plastic, selector
switches and pilot lights shall be 30.5mm type.
2.Push buttons, selector switches and pilot lights shall have electrical ratings of:
a.Dielectric strength: 2,200V for 1min.
b.Electrical design life cycles: 10,000,000 at maximum rated load
3.Push buttons, selector switches and pilot lights shall have an operating range of
minus 40-131°F (minus 40-55°C).
4.Illuminated devices shall offer universal LED that accepts 12-130 Vac/Vdc voltage
input. Lens color shall be as follows;
Running, on, open: Red.
Stopped, off, closed: Green.
Alarm: Amber.
White: Power on
Blue: All other status indications not covered by the above
Lens caps shall be approximately 0.46-inch diameter. Provide legend
faceplates engraved to indicate the required function of each device;
NEMA 4X rating.
5.Push buttons shall have a diaphragm seal for protection from liquids, particles and
corrosive agents. Button colors shall be as follows;
Start, open: Red.
Stop, close: Green.
Black: All other status indications not covered by the above
6.Selector switches shall incorporate a positive detent to prevent the switch from
hanging up between positions.
a.Selector switches shall incorporate a positive detent to prevent the switch from
hanging up between positions.
B.Potentiometer Devices
1.Potentiometer devices shall be Type 4/4X/13 corrosion-resistant/watertight/oiltight
plastic, 30.5mm type.
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0537-038-01LOW-VOLTAGE PILOT CONTROL DEVICESJANUARY 2023
2.!Potentiometer devices shall be rated for 300 Vac/Vdc, 2 W maximum (6 Vdc
minimum):
a.!Mechanical design life: Minimum 25,000 cycles
b.!Rotational torque: 3-12 in/oz
c.!Stopping torque: Minimum 12 in/lb.
3.!Potentiometer devices shall have single-turn operation, 312 degree rotation.
4.!Potentiometer devices shall be finger-safe.
C.!Elapsed Time Meters
1.!Meter shall be heavy duty, electro-mechanical, non-resettable, 6 digit 99999.9h Unit
shall be NEMA 4X rated.
2.!Mounting of unit with gasket shall maintain rating of enclosure.
2.3!OPERATOR CONTROL STATIONS
A.!Devices
1.!Control stations shall be provided with heavy industrial 30.5 mm push button(s) or
selector switch with appropriate contact action, button/lever type and color/legend
marking. Devices shall be Type 4/4X/13 corrosion-resistant/watertight/oiltight plastic.
Field mounted stop push buttons shall be supplied with pad lockable attachment to
hold the button in position.
B.!NEMA 4/13 rated:
1.!Die cast aluminum body with manufacturer's standard finish.
2.!Gasketed die cast aluminum cover with manufacturer's standard finish.
3.!Number of service mounting holes as required.
C.!NEMA 4X rated:
1.!Type 304 or 316 stainless steel body.
2.!Gasketed Type 304 or 316 stainless steel cover.
3.!Number of service mounting holes as required.
2.4!RELAYS AND TIMERS
A.!Relays Time Delay
1.!Time delay relays shall mount on tube-type bases with pin-style socket mounting.
2.!Time delay relays shall have 10 amp, B300, DPDT contact ratings and coil voltages as
shown on drawings.
3.!Time delay relays shall have adjustable timing ranges. Timing ranges shall be as
shown on drawings.
B.!Relays General Purpose
1.!General purpose relays shall have tube-base/Octal 8-pin or 11-pin terminals and "ON"
and "OFF" flag indicators.
2.!General purpose relay contacts shall be silver nickel and have 10 amp, B300, DPDT or
3PDT ratings. Coil voltages shall be as shown on drawings.
3.!General purpose relays shall have an electrical schematic on the faceplate, a clear
cover for visual inspection and snap-in marker ability.
4.!General purpose relays shall have LED status indicators, push-to-test and manual
override.
C.!Relays Miniature
1.!Miniature relays shall be square-base, 4-pole, plug-in type with blade-style terminals
and "ON" and "OFF" flag indicators.
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0537-038-01 LOW-VOLTAGE PILOT CONTROL DEVICES JANUARY 2023
2.!Miniature relay contacts shall be silver nickel and have 7 A or 10 A, DPDT or 4PDT
ratings. Coil voltages shall be as shown on drawings.
3.!Miniature relays shall have an electrical schematic on the faceplate and a clear cover
for visual inspection.
4.!Miniature relays shall have LED status indicators and push-to-test button with
incorporated manual override lever.
D.!Relays Industrial Type
1.!Industrial-type relays shall be ruggedly constructed (10 million operation mechanical
life), 2-pole or 4-pole, 8-pole, 12-pole, configured NO or NC as shown on drawings,
and panel, strip, or DIN rail mounted.
2.!Industrial-type relays shall be finger-safe.
3.!Industrial-type relay contacts shall be silver nickel with a double-break and bifurcated
design and 10A, A600 rating for ac.
4.!Accessories shall include adder decks, time delay, latching, surge suppressors and/or
mounting strip.
E.!Relays Voltage Monitoring
1.!Relays shall be ruggedly constructed (10 million operation mechanical life) and shall
be DIN rail mounted.
2.!Protective functions shall include undervoltage, overvoltage, phase imbalance, phase
loss, and phase reversal. Unit shall be capable of automatic and manual reset and
shall have LED indication.
3.!Phase imbalance, undervoltage and time dial shall be adjustable.
4.!Relay shall be self-powered, connected to load side with input fuses.
5.!Output contacts shall DPDT, 10 amp at 120 Vac, B300 pilot duty.
F.!Relays - Duplex Alternator Relay
1.!Relays shall be ruggedly constructed (10 million operation mechanical life) and shall
be tube-base/Octal 8-pin relay socket.
2.!Detects input of float switch inputs and determines outputs to turn on with line
voltage. As the lead and lead switches open, the loads remain energized. When all
switches open both loads de-energize simultaneously and the lead load alternates.
3.!Output contacts shall be SPDT 5 A at 120 Vac.
4.!LED indication shown output position.
G.!Timers Solid-State
1.!Solid-state timers shall be DIN rail-mounted.
2.!The solid-state timer contacts shall be available as SPDT or DPDT, 8 amp.
3.!Solid-state timers shall be available with On-Delay, Off-Delay, On-Delay and Off-
Delay, One-Shot, and Flasher operating modes as required on the drawings.
4.!Solid-state timers shall have coil surge protection and adjustable timing ranges of
0.05 sec to 60 hours as shown on drawings.
H.!Timers Programmable
1.!Programmable timers shall be digital timing relays with LCD display and shall be
socket or panel mounted.
2.!Programmable timer contacts shall be SPDT, rated 5 A, B300.
3.!Programmable timer panel surface shall offer Type 4X/IP66 protection.
4.!Programmable timers shall be configurable for "SIGNAL ON-DELAY", "POWER ON-
DELAY", "OFF-DELAY", "REPEAT CYCLE", "ONE-SHOT", and "CUMMULATIVE"
operating modes as required on the drawings.
5.!Programmable timers shall have timing ranges of 0.000 sec. to 9999 hours depending
on selected mode and as shown on drawings.
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0537-038-01 LOW-VOLTAGE PILOT CONTROL DEVICES JANUARY 2023
2.5!MINIATURE CIRCUIT BREAKERS
A.!Miniature circuit breakers shall be thermal-magnetic, current-limiting type, sized as specified
on the drawings:
1.!0.5-63 A current rating
2.!1-pole, 2-pole, or 3-pole
3.!Type C or Type D tripping characteristic
B.!Miniature circuit breakers shall be UL Listed.
C.!Miniature circuit breakers shall be rated for:
1.!Voltage: Maximum 480Y/277 Vac (UL/CSA)
2.!Interrupting capacity: 10 A (UL/CSA)
D.!Housing shall satisfy Insulation Group II/RAL 7035, shall have IP20 finger-safe design, shall
be suitable for DIN rail mounting and shall include status indicator window and scratch- and
solvent-resistant printing.
E.!Miniature circuit breakers shall support reversible line and load connections and shall have
dual terminals that:
1.!Connect up to 4 wires, or 2 wires and a bus bar.
2.!Clamp from both sides.
3.!Have a unique design that directs wires into openings to prevent wiring misses.
F.!Miniature circuit breakers shall be compatible with UL 508 Listed bus bars, auxiliary contacts,
signal contacts, shunt trips and toggle-mount lockout attachments.
2.6!TERMINAL BLOCKS AND FUSE BLOCKS
A.!Terminal Blocks: Control, No. 22 to No. 8 AWG
1.!Control terminal blocks shall be screw-type, feed-through.
2.!Nickel-Plated terminals and stainless steel screws.
3.!Control terminal blocks shall be certified:
a.!UR/CSA: No. 22 to No. 8 AWG wire range, 50 A maximum current, 600 Vac/Vdc
rating
4.!Control terminal blocks shall have a snap-in card marking system.
B.!Terminal Blocks Power
1.!Power terminal blocks shall be one of the following styles;
a.!Mini-block: 3-pole, rated at 600 Vac/Vdc, 115 A
b.!Open-style power distribution block with copper connectors: 3-pole or 1-pole,
rated at 600 Vac/Vdc, 175-760A
c.!Open-style feed-through/splicer terminal block with copper connectors: 3-pole
or 1-pole, rated at 600 Vac/Vdc, 175-760 A
2.!Power terminal blocks shall be certified by UR, CSA and CE.
3.!Wire ranges and tightening torques shall be labeled on the block.
4.!Power terminal blocks shall have a write-on marking surface or marker retention
feature.
C.!Fuse Blocks
1.!Fuse block kits shall be used for protection of transformers and control circuits
capable of delivering no more than 200,000 RMS symmetrical Amps, 600 V maximum.
2.!Fuse block kits shall be 1-pole, 2-pole or 3-pole.
3.!Each pole shall have a fuse cover.
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0537-038-01 LOW-VOLTAGE PILOT CONTROL DEVICES JANUARY 2023
2.7!PANEL MOUNT SIGNALING ALARM
A.!Combined Sounder and LED Beacon
1.!The combined sounder and flashing LED beacon shall have polycarbonate housing
and lens, 45 mm size, 22 mm mounting hole, and Type 4/4X/13, IP65/IP66 ingress
rating as required on the drawings.
2.!Control logic shall be provided so that the unit can be silenced until the alarm is
cleared and reset.
3.!The sounder shall have an average of 103 dBA at 1 m and shall be configured as
pulsing.
2.8!CURRENT LOOP SIGNAL SURGE PROTECTOR
A.!Signal conditioner/isolator shall be provided for each analog input/output signal leaving
panel.
1.!High-density device: 6 mm wide, current/voltage isolator
B.!The signal conditioner/isolator shall mount on DIN rail and provide local status indications
2.9!ENCLOSURE BREATHER/DRAIN
A.!Provide enclosure breather/drain on all wall or switchrack mounted enclosures mounted
outdoors or indoors in non-air-conditioned rooms. Breather/Drain shall be Type 316
Stainless, 3/4-inch size and shall not violate NEMA rating of enclosure. Breather/Drain shall
be similar Crouse-Hinds, ACD Series.
2.10!TEMPERATURE CONTROL
A.!Provide thermostatic controlled heaters on all panels mounted outdoors or as indicated on
the drawings. Heating element shall be Positive Temperature Coefficient (PTC). Heaters shall
be sized to protect equipment for low temperatures, condensation, and corrosion.
2.11!POWER SUPPLIES
A.!Control Power Transformer
1.!The control power transformer shall be epoxy encapsulated 120 V secondary and shall
offer finger-safe protection. Control transformer shall be UL 5085 listed.
2.!The control transformer shall have dual primary and secondary fuses.
3.!The control transformer shall have sufficient capacity to operator integral device,
remotely located pilot, indicating, control devices, motor winding heater and panel
heater.
4.!The control transformer shall be sized with a 200 VA spare capacity.
B.!24 Vdc Power Supplies
1.!24 Vdc power supplies shall be switched, DIN rail mounted, screw terminals,
temperature range of minus 0 to plus 60ºC.
2.!24 Vdc power supplies shall have low inrush current and shall incorporate a minimum
120% Power Burst design.
PART 3 - EXECUTION
3.1!DELIVERY, STORAGE AND HANDLING
A.!The supplier shall coordinate the shipping of equipment.
B.!The supplier shall store the equipment in a clean and dry space.
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0537-038-01 LOW-VOLTAGE PILOT CONTROL DEVICES JANUARY 2023
C.!The supplier shall protect the devices from dirt, water, construction debris, and traffic.
3.2!INSTALLATION
A.!The supplier shall verify all settings have been properly adjusted prior to energizing.
B.!The supplier shall ensure accessibility to electrical control devices.
3.3!OPERATOR CONTROL STATIONS
A.!Permitted uses of NEMA 4/13 Enclosure:
1.!Indoor spaces that are dry, ventilated or air-conditioned spaces.
B.!Permitted uses of NEMA 4X Enclosure:
1.!All outdoor spaces.
2.!Indoor spaces that are damp, wet, or in chemical areas.
END OF SECTION
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0537-038-01 LOW-VOLTAGE PILOT CONTROL DEVICES JANUARY 2023
SECTION 26 41 00
FACILITY LIGHTNING PROTECTION
PART 1 - GENERAL
1.1!RELATED DOCUMENTS
A.!Drawings and general provisions of the Contract, including General and Division 1
Specification Sections, apply to this Section.
1.2!SUMMARY
A.!This Section includes lightning protection for the structures, internal & external operational
equipment, all contents, and occupants by preventing damage to the structure caused by
lightning
1.3!STANDARDS:
A.!The following specifications and standards of the latest issue form a part of this
specification:
1.!Underwriters Laboratories, Inc. Installation requirements UL 96A
2.!National Fire Protection Association, Installation NFPA 780 2014 edition
1.4!SUBMITTALS
A.!Product Data: For air terminals and mounting accessories.
B.!Shop Drawings: Detail lightning protection system, including air-terminal locations,
conductor routing and connections, and bonding and grounding provisions. Include
indications for use of raceway, data on how concealment requirements will be met, and
calculations required by NFPA 780 for bonding of grounded and isolated metal bodies.
C.!Qualification data for firms and persons specified in "Quality Assurance" Article to
demonstrate their capabilities and experience. Include data on listing or certification by an
NRTL or LPI.
D.!Certification, signed by CONTRACTOR, that roof adhesive for air terminals is approved by
manufacturer s of both the terminal assembly and the single-ply membrane roofing
material.
E.!Field inspection reports indicating compliance with specified requirements.
1.5!QUALITY ASSURANCE
A.!Installer Qualifications: Engage an experienced installer who is an NRTL or who is certified by
LPI as a Master Installer/Designer.
B.!The lightning protection system shall conform to the requirements and standards for
lightning protection systems of UL and NFPA. Upon completion, application shall be made to
the Underwriters Laboratories, Inc. for inspection and issuance of the UL Master Label and
LPI-177 certification and inspection.
C.!The system to be furnished under this specification shall be the standard product of a
manufacturer regularly engaged in the production of lightning protection equipment and
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0537-038-01 FACILITY LIGHTNING PROTECTION APRIL 2022
properly UL labeled. All equipment shall be new and of a design and construction to suit the
application where it is used in accordance with accepted industry standards as well as UL
and NFPA requirements.
1.6!COORDINATION
A.!Coordinate installation of lightning protection with installation of other building systems and
components, including electrical wiring, supporting structures, and building materials; metal
bodies requiring bonding to lightning protection components; and building finishes.
B.!Coordinate installation of air terminals attached to roof systems with roofing manufacturer
and Installer.
PART 2 - PRODUCTS
2.1!MANUFACTURERS
A.!Available Manufacturers: Subject to compliance with requirements, manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
1.!Automatic Lightning Protection.
2.!ERICO International Corporation.
3.!Harger Lightning Protection, Inc.
4.!Heary Bros. Lightning Protection Co. Inc.
5.!Independent Protection Co.
6.!Robbins Lightning Inc.
7.!Thompson Lightning Protection, Inc.
2.2!LIGHTNING PROTECTION SYSTEM COMPONENTS
A.!Provide and install a complete lightning protection system in compliance with the
specifications and standards of the most current editions of the National Fire Protection
rs Laboratories
Lightning Protection Standard UL 96 A. A lightning protection CONTRACTOR who is listed by
Underwriters Laboratories, Inc. and a certified Master Installer by the Lightning Protection
Institute shall install the system.
B.!Material Requirements:
1.!All lightning protection materials and components shall comply in weight, size and
composition with class II UL 96 and NFPA 780 lightning protection material
requirements. All materials shall be UL listed for lightning protection.
2.!Copper materials shall not be mounted on aluminum, Galvalume, galvanized steel or
zinc surfaces. This includes those materials that have been painted.
3.!Aluminum materials shall not come into contact with earth or where rapid
deterioration is possible. Aluminum materials shall not come into contact with copper
surfaces or where exposed to runoff from copper surfaces. Aluminum materials shall
not be attached to surfaces covered with alkaline-based paint, embedded in concrete
or masonry, or installed in a location subject to excessive moisture.
4.!Copper shall be used on all non-aluminum areas
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0537-038-01 FACILITY LIGHTNING PROTECTION APRIL 2022
a.!Air terminals shall be a minimum of 1/2x12 inch solid copper
b.!Cable shall be 28 strands of .066 inch diameter cable. 133,500 circular mils.
c.!Connectors and splicers: Cast bronze mechanical with stainless steel bolt and
nut.
d.!Counterpoise shall utilize exothermic type connections to steel cable splicing
and cable to ground rods.
e.!Fasteners shall be copper with stainless steel anchors on masonry locations and
stainless steel screws on wood and metal locations
5.!Aluminum materials shall be used on all HVAC units, roof perimeters, and other roof
surfaces that are aluminum. If the parapets utilize aluminum coping the roof system
shall be completely aluminum except for down conductors & grounding equipment.
a.!Air terminals shall be a minimum of 5/8x12 inch solid aluminum
b.!Cable shall be 37 strands of .0756 diameter cable. 211,600 circular mils.
c.!Connectors and splicers: Cast aluminum mechanical with stainless steel bolt and
nut. Exothermic type for grounding connections and splicing below grade
d.!Fasteners shall be aluminum with stainless steel anchors on masonry locations
and stainless steel screws on wood and metal locations
C.!Air Terminals
1.!Air terminals shall extend a minimum of 10 inches above the object or area they are to
protect. Air terminals shall be located at intervals not exceeding 20 feet along ridges
of pitched roofs and along the perimeter of flat or gently sloping roofs (flat or gently
sloping roofs include roofs that have a pitch less than 3:12). Flat or gently sloping
roofs exceeding 50 feet in width shall be provided with additional air terminals
located at intervals not exceeding 50 feet. Air terminals shall be located within 2 feet
of the ends of ridges, roof edges and outside corners of protected areas.
2.!Air terminals shall be installed on stacks, flues, mechanical units and other objects not
located within a zone of protection. Permanent metal objects on the structure having
an exposed metal thickness of 3/16 inches or greater may be substituted for air
terminals and shall connected to the lightning protection system as required by the
specified standards using main size conductor and bonding plates having a minimum
of 3 square inches of surface contact area.
3.!Air terminal bases shall be securely fastened to the structure in accordance with the
specified standards. Fasteners may include stainless steel screws, bolts, nails, anchors
or adhesive. Adhesive shall be compatible with the surface on which it is used. Any
protective sheets or pads that may be required by the roofing manufacturer shall be
furnished and installed by the roofing CONTRACTOR.
4.!Main conductors shall be sized as Class I or Class II materials in accordance with the
specified standards. Conductors shall provide a 2 way, horizontal or downward path
from each strike or air terminal to connections to the lightning protection ground
electrode system. Conductors shall be free of excessive splices and no bend of a
conductor shall form an included angle of less than 90 degrees nor have a radius of
bend less than 8 inches.
5.!Conductors shall be securely fastened to the structure on which they are placed at
intervals not exceeding 3 feet. Fasteners shall be of the same material or of a material
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equally resistant to corrosion as that of the conductor. Any protective sheets or pads
that may be required by the roofing manufacturer shall be furnished and installed by
the roofing CONTRACTOR.
6.!Connector fittings shall be listed for the purpose and of the same material as the
conductor or of electrolytically compatible materials.
7.!Down conductors shall be sized as Class II materials in accordance with the specified
standards. Class II conductors from a higher portion of a structure shall continue to
connections to the lightning protection ground electrode system. Down conductors
shall be spaced at intervals averaging not more than 100 feet around the perimeter of
the structure. In no case shall a structure have fewer than 2 down conductors. Where
down conductors are installed exposed on the exterior of a structure and are subject
to physical damage or displacement, guards shall be used to protect the conductor a
minimum of 6 feet above grade. Metallic guards shall be bonded at each end.
8.!In case of structural steel frame construction, down conductors may be omitted and
roof conductors shall be connected to the structural steel frame at intervals not
exceeding 100 feet along the perimeter of the structure.
D.!Roof Penetrations
1.!Roof penetrations required for down conductors or for connection to structural steel
framework shall be made using thru-roof assemblies with solid riser bars or conduits
and appropriate roof flashing. Conductors shall not pass directly through the roof. The
roofing CONTRACTOR shall furnish and install the materials required to properly seal
all roof penetrations of the lightning protection components and any additional
roofing materials or preparations required by the roofing MANUFACTURER for
lightning conductor runs to assure compatibility with the warranty for the roof
including roof pads that may be required to protect the roof under each of the
lightning protection components.
E.!Ground Electrodes:
1.!Each down conductor shall terminate at a ground electrode dedicated to the lightning
protection system, or to a building or facility ground electrode system that consists of
multiple ground electrodes that are interconnected with a ground ring conductor.
2.!Ground rod electrodes shall be copper-clad steel, a minimum 3/8 inch diameter and
10 feet long. The down conductor shall be connected to the ground electrode using a
bronze ground rod clamp having a minimum of 1-1/2 inch contact between the
ground rod electrode and the conductor measured parallel to the axis of the ground
rod electrode, or by an exothermically welded connection. Ground rod electrodes
shall be located a minimum of 2 feet below grade and shall be installed below the
frost line where possible (excluding shallow topsoil conditions).
3.!Where it is not possible to drive ground rod electrodes because of bedrock or shallow
topsoil conditions, ground plate electrodes, radial electrodes, ground ring electrodes,
concrete-encased electrodes, or combinations of these may be used in accordance
with NFPA 780.
4.!Where the structural steel framework is utilized as down conductors for the system,
ground electrodes shall be connected to columns around the perimeter of the
structure at intervals averaging not more than 60 feet apart. Columns shall be
grounded using either bonding plates having 8 square inches of surface contact area
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or by exothermically welded connections.
F.!Common Bonding of Grounded Systems
1.!Common bonding of all grounded systems within the building shall be ensured by
interconnecting them to the lightning protection system using main size conductor
and fittings.
2.!For structures the interconnection of the lightning protection system ground
electrodes and other grounded systems shall be in the form of a ground loop
conductor.
3.!These grounded systems shall include but are not limited to the electrical service,
communication, and antenna system grounds as well as all underground metallic
piping systems including water, gas, sewer, underground metallic conduits, etc.
meter.
G.!Potential Equalization
1.!Grounded metal bodies located within the required bonding distance as determined
by the bonding distance formula in NFPA 780 shall be bonded to the lightning
protection system using the required bonding conductors and connections.
PART 3 - EXECUTION
3.1!INSTALLATION OF CONDUCTORS
A.!General: Conductors shall be installed to interconnect all air terminals to the system of
grounding electrodes, and in general provide a minimum of at least 2 paths to ground from
any air terminal on the system. Conductors shall provide a horizontal or downward path
between the system air terminals and grounding electrode system.
B.!Routing: Conductors shall be routed in such a manner that maximum concealment from
public view is achieved. Down conductors may be installed in 1-inch PVC conduit from roof
to grade.
C.!Counterpoise Conductors: Counterpoise conductors shall be installed after finished grades
are established to insure specified depth and to minimize the possibility of damage. Any
counterpoise conductor which is cut or damaged shall be repaired or replaced with no
additional cost to the contract.
D.!Connections: All connections between conductors below grade shall be exothermically
welded. Improper application of weld shall be replaced at no additional cost to the contract.
3.2!INSTALLATION OF GROUND RODS
A.!General: Ground rods shall be installed vertically at each down conductor position at a
minimum of 2 feet from the building foundation wall. Inspection and documentation at each
grounded location, weld, depth of counterpoise, etc., shall be made prior to backfill.
CONTRACTOR shall notify ENGINEER in writing to request inspection of underground work
and for LPI inspection before backfill. Allow a minimum of 1 week for ENGINEER to make the
inspection after notification from CONTRACTOR.
B.!Test Wells and Inspection Wells: Provide prefabricated test and inspection wells for all
ground rods installed in paved or concrete areas.
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3.3!BONDING OF SECONDARY METALLIC BODIES
A.!Structure Grounding: Provision shall be made at the roof level on reinforced concrete
structures for bonding between the roof or down conductors, metallic elements of the roof
system and metallic exterior wall systems.
B.!Bonding: All down conductors run in concrete columns shall be bonded to the reinforcing
steel at the top and the bottom of the column.
3.4!GENERAL WORKMANSHIP
A.!General: All elements of the Lightning Protection System shall be installed in a professional
and workmanlike manner consistent with the best industry practices.
B.!Concealed Installation: All system components shall be concealed to the maximum extent
possible to preserve the aesthetic appearance of the project building on which the system is
installed.
3.5!COORDINATION WITH OTHER TRADES
A.!Coordination: The CONTRACTOR shall coordinate his work with all trades, to ensure the use
of proper materials and procedures in and around the roof in order not to jeopardize the
roofing warranty.
B.!Fasteners: Where fasteners are to be embedded in masonry or the structural system, they
shall be coordinated to insure installation at the proper time of construction.
3.6!CORROSION PROTECTION
A.!Do not combine materials that can form an electrolytic couple that will accelerate corrosion
in the presence of moisture unless moisture is permanently excluded from junction of such
materials.
B.!Use conductors with protective coatings where conditions would cause deterioration or
corrosion of conductors.
3.7!INSPECTION, CERTIFICATION AND MAINTENANCE
A.!At completion of the installation of the lightning protection system, the CONTRACTOR shall
apply for inspection of the system by UL field representatives. The system is to be inspected
for compliance with NFPA 780.
B.!If the lightning protection system covers an entire independent structure and the system
passes inspection, UL will issue a Master Label® Certificate of Inspection for Lightning
Protection System. The CONTRACTOR will submit the certificate for distribution to the
certificate to the UL website, https://lps.ul.com where it may be viewed by consumers,
building OWNERs, insurance agencies and other interested parties. The Master Label
Certificate of Inspection is valid for a period of 5 years. If the building changes structurally or
if modifications are made to the system during that period, the certificate is no longer valid.
C.!If the scope of the lightning protection system is limited by contractual or other reasons, the
installer may limit the scope of the UL inspection. In those cases where the entire system is
not inspected, a Master Label Certificate of Inspection will not be issued by UL. They will
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issue a Letter of Findings of their inspection indicating compliance with the limited scope of
the inspection.
D.!At project closeout, the CONTRACTOR shall provide the OWNER with accurate as-built
drawings as well as recommended guidelines for maintenance of the system.
END OF SECTION
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27 15 23 FIBER OPTIC EQUIPMENT
1.00GENERAL
1.01SCOPE OF WORK
A.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
B.PCSI shall provide a complete and functional fiber optic communications infrastructure
including, but not limited to, fiber optic cable (FOC), patch panels, installation,
terminations, testing, and implementation as shown on the Drawings and specified herein.
C.Field verify all cable lengths prior to shop drawing submittals and construction.
1.02RELATED WORK
A.Refer to Division 01 Section 01 66 00, Product Delivery, Storage, and Handling.
B.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
1.03SUBMITTALS
A.Refer to Division 01 for general submittal requirements.
B.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
C.Product Data
1.Detailed bill of materials for all fiber-optic cable, terminations, patch panels, breakout
enclosures, splice kits, connectors, pigtails, fan-outs, etc., to be provided.
2.Complete manufacturer catalog data that identifies materials and options. Product
data sheets shall include the manufacturer's name and catalog number for each item,
the manufacturer's descriptive literature, catalog cuts, and any power supply
requirements.
3.Manufacturer installation instructions.
4.Catalog data on all testing devices proposed for use plus certifications of accuracy,
calibration, and traceability to standards of the National Institute for Standards and
Testing.
D.Shop Drawings
1.Diagram drawings of the complete fiber-optic system indicating the locations of all pull
boxes, patch panels, termination points, or breakout enclosures.
2.Develop a fiber optic naming convention and schedule to label all distribution cables
(at each end) with termination location information, and fiber optic patch panel layout
schedules that identify all termination panel and port connection assignments.
3.Provide fiber optic termination schedule report to include the following at a minimum:
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a.Overall fiber optic backbone schedule including cable identifier, number of fibers,
from panel reference location, and to panel reference location for all fiber optic
backbone segments provided.
b.Patch panel termination schedule including:
c.Diagram of all patch panel modules, empty slots, and used and unused ports.
Patch panel modules shall receive an alphabetical designator. Patch panel module
ports shall receive a numeric designator.
d.Bulk cable termination schedule identifying bulk cable, fiber number, fiber color,
port termination number, and patch cable terminations. Provide for all bulk
cables terminated.
E.Samples
1.Provide one sample of each type of cable, splice, and connector termination kit. One
sample of a completed example of each type of splice and connector termination shall
be submitted.
2.Provide sample of cable labels with intended labeling convention.
3.Provide sample of fiber optic termination schedule to be installed at each patch panel.
F.Calculations
1.The Fiber Optic System Supplier shall provide a fiber optic power budget for each cable
run in excess of 1000 feet. The budget shall include:
a.Minimum transmit power and receiver sensitivity for all active devices.
b.Available power and losses for each segment, in dBm, including cable attenuation
and connector losses. Use manufacturer data for cable attenuation and a 0.5 dB
loss per connector shall be assumed.
c.A 3 dBm aging margin and 10 dB safety margin shall be included in all segment
power budgets.
2.Installation Work Plan
a.Submit a cable pull and splicing work plan a minimum of 45 days before initiation
of any cable pulling. The cable pulling and splicing work plan must be approved a
minimum of 15 days before pulling cable. Include the following:
1)Pull tension calculations.
2)Detailed description of pull operation methods for all conduit runs.
3)Tools and equipment to be used for cable installation and testing.
4)Physical location of equipment setup and type.
5)Exact locations of splice points.
6)Safety and manual assist cable-pulling operations.
7)Detailed schedule for pulling and testing cables.
8)The name and qualifications of the supervisory personnel directly
responsible for the installation of the conduit system.
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9)Sample fiber optic cable test sheets.
10)All signed test sheet results.
G.Test Reports
1.Submit the results of all specified testing.
2.Test forms shall include the following information at a minimum:
a.Refer to Paragraph 3.05-E for specific test documentation requirements.
b.Test type.
c.Test location.
d.Date and time the test results were saved in the memory of the tester.
e.Wavelength.
f.Index of refraction.
g.Cable identification.
h.Fiber type.
i.Fiber number in accordance with the specified naming convention.
j.Fiber color.
k.Result of the value of the tested parameter.
l.The overall Pass/Fail evaluation of the link-under-test including the Attenuation
worst-case margin (margin is defined as the difference between the measured
value and the test limit value).
m.Electronic documentation of general and detailed test information.
3.Furnish hard copy and electronic copy for all OTDR traces.
4.Submit certification that the fiber optic cable has passed each testing stage:
a.Submit separate documentation for each testing stage result.
H.O&M Manual.
1.Refer to Division 1 Section 40 61 00 for general O&M requirements.
2.O&M shall include product data, shop drawings, calculations, test reports, and fiber
optic termination schedules/reports.
3.Fiber drawings must reflect any and all changes to the fiber cable plant
interconnectivity. These notes should be reflected on the fiber interconnectivity
drawings.
1.04REFERENCE STANDARDS
A.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
B.American National Standards Institute / Telecommunications Industry Association
(ANSI/TIA)
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1.ANSI/TIA-568-D.0, Generic Telecommunications Cabling for Customer Premises
2.ANSI/TIA-568-D.1, Commercial Building Telecommunications Cabling Standard Part 1:
General Requirements
3.ANSI/TIA-568-D.3, Optical Fiber Cabling Components Standard
4.ANSI/TIA-758-B, Customer-Owned Outside Plant Telecommunications Infrastructure
Standard
5.ANSI/ICEA S-87-640, Optical Fiber Outside Plant Communications Cable
C.Telecommunications Industry Association/ Electronic Industries Association (TIA/EIA)
1.TIA/EIA-606-C: Administrative Standard for Telecommunications Infrastructure
2.EIA-492AAAx - Detail Specification for… Class 1a Graded-Index Multimode Optical
Fibers.
3.EIA-526-14-A, OFSTP 14A - Optical Power Loss Measurements of Installed Multi-mode
Fiber Cable Plant.
4.EIA-526-7, OFSTP 7 - Measurement of Optical Power Loss of Installed Single-Mode
Fiber Cable Plant.
5.EIA-455 - Standard Test Procedure for Fiber Optic Fibers, Cables, Transducers, Sensors,
Connecting and Terminating Devices, and Other Fiber Optic Components.
6.EIA-598-A - Optical Fiber Cable Color Coding.
7.EIA TSB-140, Additional Guidelines for Field-Testing Length, Loss and Polarity of Optical
Fiber Cabling Systems.
D.The Fiber Optic Association (FOA)
1.FOA-1 - Testing Loss of Installed Fiber Optic Cable Plant, (Insertion Loss, TIA OFSTP-14,
OFSTP-7, ISO/IEC 61280, ISO/IEC 14763, etc.).
2.FOA-2 - Testing Loss of Fiber Optic Cables, Single Ended, (Insertion Loss, TIA FOTP-171,
OFSTP-7, ISO/IEC 14763).
3.FOA-3 - Measuring Optical Power (Transmitter and Receiver Power, FOTP-95,
Numerous ISO/IEC standards).
4.FOA-4 - OTDR Testing of Fiber Optic Cable Plant (TIA FOTP-8/59/60/61/78, ISO/IEC
14763, etc.).
5.FOA-5 - Fiber Optic Datalinks.
E.Insulated Cable Engineers Association (ICEA)
1.ICEA 5-83-696 - Fiber Optic Premises Distribution Cable (Indoor/Outdoor).
2.S-83-596 - Optic Fiber Premises Distribution Cables.
3.S-87-640 - Optic Fiber Outside Plant Communications Cable.
4.S-104-696 - Fiber Optic Premises Distribution Cables.
F.International Electrotechnical Commission (IEC)
1.ISO/IEC 11801 – Generic Cabling for Customer Premises.
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2.IEC 60793-2-10 - Product Specifications - Sectional Specification for Category A1
Multimode Fibers.
G.Military Standard (MIL)
1.MIL-202 - Test Methods for Electronic and Electrical Component Parts.
2.MIL-454 - Standard General Requirements for Electronic Equipment.
3.MIL-810 - Environmental Test Methods and Engineering Guidelines.
H.National Fire Protection Association (NFPA)
1.National Electrical Code (NEC) Article 770.
2.NFPA 262 – Standard Method of Test for Flame Travel and Smoke of Wires and Cables
for Use IN Air-Handling Spaces.
I.Telcordia Standards
1.GR-409 - Generic Requirements for Indoor Fiber Optic Cable.
J.Telecommunication Standardization Sector of the International Telecommunications Union
(ITU-T)
1.ITU-T G.651.1 - Characteristics of a 50/125 um Multimode Graded Index Optical Fiber
Cable for the Optical Access Network.
2.ITU-T G.652 - Characteristics of a single-mode optical fiber and cable.
K.Underwriters Laboratories, Inc. (UL)
1.UL 1581 VW 1 - Vertical Tray Cable Flame Test.
2.UL 1666 - UL Standard for Safety Test for Flame-Propagation Height of Electrical and
Optical-Fiber Cables Installed in Vertical Shafts.
1.05QUALITY ASSURANCE
A.All fiber optical cables shall be constructed in accordance with EIA-455, and 100 percent of
all optical fibers and jacketing shall meet or exceed the requirements contained in this
specification.
B.The cable manufacturer shall be ISO 9001 certified and registered.
C.The fiber optic cabling system materials furnished under this Section shall be provided by
Fiber Optic Suppliers who have been providing these types of materials for the past three
years. The Fiber Optic Suppliers shall provide personnel capable of providing technical
assistance during installation.
D.The installation of fiber optic cabling system materials furnished under this Section shall be
performed by an installation Contractor who has been installing these types of materials
and systems for the past three years.
E.Supplier must furnish five working installation references.
F.All test equipment shall be calibrated by the manufacturer.
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1.06DELIVERY, STORAGE, AND HANDLING
A.The cable shall be packaged in cartons and/or wound on spools or reels. Each package shall
contain only one continuous length of cable. The packaging shall be constructed so as to
prevent damage to the cable during shipping and handling.
B.When the length of an order requires a large wooden reel, the cable will be covered with a
three-layer laminated protective material. The outer end of the cable shall be securely
fastened to the reel head so as to prevent the cable from becoming loose in transit. The
inner end of the cable shall project into a slot in the side of the reel or into housing on the
inner slot of the drum, in such a manner and with sufficient length to make it available for
testing.
C.Test tails shall be at least 2 meters long. The inner end shall be fastened so as to prevent
the cable from becoming loose during shipping and installation. Reels shall be permanently
marked with an identification number that can be used by the manufacturer to trace the
manufacturing history of the cable and fiber.
D.Wooden reels shall be plainly marked to indicate the direction in which it should be rolled
to prevent loosening of the cable on the reel.
E.All fiber optic cables shall be attenuated tested. The attenuation of each fiber shall be
provided with each cable reel by the manufacturer.
F.The attenuation shall be measured at 1310 nm and 1550 nm for single-mode fibers and 850
nm and 1300 nm for multimode fiber cables after received on site. The manufacturer shall
submit the test results prior to installation of the cable.
G.Packaging
1.The completed cable shall be packaged for shipment on non-returnable wooden reels.
It is the responsibility of the Contractor to determine all required cable lengths.
2.Top and bottom ends of the cable shall be available for testing.
3.Both ends of the cable shall be sealed to prevent the ingress of moisture.
4.Each reel shall have a weatherproof reel tag attached identifying the reel and cable.
5.Each cable shall be accompanied by a cable data sheet.
1.07WARRANTY
A.Provide warranty per Division 01, Warranties and Bonds.
B.Testing and certification of the fiber optic cabling shall be by the installer and shall include
the provision of a Manufacturer Warranty covering performance, products and installation.
Provide certificate and documentation for the manufacturer warranty.
1.08LABELLING
A.The labeling of network components, structured cabling, and cable routing shall comply
with the TIA/EIA-606 standard.
B.As a minimum, fiber-optic backbone cables are to be labeled at both ends of the cable.
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C.In addition, the fiber backbone cables are to be labeled at each transition. A transition is
defined as: a change in ducting (e.g., cable tray to conduit), a pull hole, a pull box, a change
in direction of more than 45 degrees, or an entrance and exit of ducting through a wall or
floor.
D.The tagging convention for identification of fiber-optic backbone cables shall
indicate the source and destination of the cable separated by a colon.
2.00PRODUCTS
2.01GENERAL
A.Products which serve similar functions shall be from the same manufacturer and part
number. If this commonality requirement cannot be met, indicate the reason for not
meeting it during the submittal process.
B.All network components of a single type shall be from the same manufacturer and the
same manufacturer’s catalogue number.
C.All network sub-system components shall be from the same manufacturer.
2.02MANUFACTURERS
A.Corning Cable Systems Corp.
B.Approved Equal.
2.03OPTICAL FIBER CHARACTERISTICS
A.All fibers in the cable must be functional (undamaged) and meet specification
requirements.
B.Each optical fiber shall consist of a doped silica core surrounded by a concentric silica
cladding. The fiber shall be matched clad design.
C.Provide multimode and/or single mode, optical glass fiber compatible with LED or laser-
based transmission systems as specified herein.
D.For existing system expansion or repair, optical fiber and equipment types used shall be
compatible with existing system, to the furthest extent possible. Connecting 50 µm fiber
directly to 62.5 µm fiber is not acceptable.
E.For new systems, existing system upgrades or replacements optical fiber and equipment
types used shall support 1 GB optimized data rates for all connected segments for distances
of up to 1000 meters.
2.04LOOSE TUBE - INDOOR/OUTDOOR OPTICAL FIBER
A.Provide all-dielectric loose tube and water blocked type fiber optic cable for all outdoor and
indoor/outdoor segments. Cable shall meet UL OFNR specifications and not require
transition splicing upon building entry in order to meet fire codes.
B.Cable shall be flame-retardant, UV stabilized, fully water blocked for use in indoor/outdoor
applications. Cable shall be suitable for installation in duct, aerial, cable tray, and riser
environments.
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C.Optical fibers shall be placed inside a buffer tube. Each buffer tube shall contain up to 12
fibers. In buffer tubes containing multiple fibers, the colors shall be stable across the
specified storage and operating temperature range and not subject to fading or smearing
onto each other or into the waterblock filling material. Colors shall not cause fibers to stick
together. Buffer tubes shall be kink-resistant within the specified minimum bend radius.
Fillers may be included in the cable core to lend symmetry to the cable cross-section where
needed. The central anti-buckling member shall consist of a glass-reinforced plastic rod.
The purpose of the central member is to prevent buckling of the cable.
D.The cable core shall contain a water-blocking material. The water-blocking material shall
be non-nutritive to fungus, electrically non-conductive, and homogenous. It shall also be
free from dirt and foreign matter and shall be readily removable with conventional non-
toxic solvents. Cable shall contain water-blocking threads between tubes. The cable shall
contain at least one ripcord under the sheath for easy sheath removal.
E.Tensile strength shall be provided by a combination of high tensile strength dielectric yarns.
The high tensile strength dielectric yarns shall be helically stranded evenly around the cable
core.
F.All dielectric cables (with no armoring) shall be sheathed with medium density
polyethylene (MDPE). The minimum normal jacket thickness shall be 1.4 mm. Jacketing
material shall be applied directly over the tensile strength members and water-blocking
material. The polyethylene shall contain carbon black to provide ultraviolet light protection
and shall not promote the growth of fungus.
G.Armored cables shall have armor composed of a corrugated steel tape, plastic-coated on
both sides for corrosion resistance, and shall be applied with on an overlapping seam with
the corrugations in register. All armor splices shall be recoated with plastic to maintain the
armor’s corrosion resistance. The outer jacket shall be applied over the corrugated steel
tape armor. The outer jacket shall be a medium density polyethylene with a minimum
nominal jacket thickness of 1.25 mm. The polyethylene shall contain carbon black to
provide ultraviolet light protection and shall not promote the growth of fungus.
H.Loose tube indoor/outdoor fiber optic cable type shall be selected from and meet the
requirement of the following table, based on the specific application and performance
requirements:
OM1 / A1b OS2 / B1.3
OM3 / A1a.2
62.5 µm Legacy Single Mode
50 µm Laser
Function Multi Mode Multi Mode Single Mode
Core Diameter 62.5 +/- 3.0 µm 50 +/- 3.0 µm 9 +/- 1.0 µm
Loose Tube Loose Tube
Cable Type Loose Tube
Waterblock Waterblock
Waterblock
EIA/TIA-492AAAA EIA/TIA-492CAAB
Reference Standards EIA/TIA-492AAAC
IEC-60793 IEC-60793
IEC-60793
ISO/IEC-11801 ISO/IEC-11801
ISO/IEC-11801
Core Non-Circularity
Cladding Diameter 125.0 +/- 2.0 µm 125.0 +/- 2.0 µm 125.0 +/- 1.0 µm
Core-to-Cladding Concentricity
Cladding Non-Circularity
Coating Diameter 245 +/- 10 µm 245 +/- 10 µm 245 +/- 10 µm
Colored Fiber Nominal Diameter 253-259 µm 253-259 µm 242 +/- 7 µm
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OM1 / A1b OS2 / B1.3
OM3 / A1a.2
62.5 µm Legacy Single Mode
50 µm Laser
Cabled Fiber Attenuation
850 nm 1310 nm
850 nm
1300 nm 1550 nm
1300 nm
Point Discontinuity
1310 & 1550 nm
850 & 1300 nm 850 & 1300 nm
Macrobend Attenuation
@ 850 & 1300 nm @ 1310 & 1550 nm
@ 850 & 1300 nm
for 100 turns about 75mm OD for 100 turns about 50mm OD
for 100 turns about 75mm OD
mandrel mandrel
mandrel
200
Minimum Effective Modal Bandwidth 2000 n/a
MHz*km
MHz*km
200 @ 850 nm
Minimum Overfilled Launch Bandwidth 1500 @ 850 nm n/a
500 @ 1300 nm
\[MHz*km\] 500 @ 850 nm
300m @ 850 nm 40km @ 1310 nm
IEEE 802.3 GbE Distance (Min) 1000m @ 850 nm
500m @ 1300 nm 70km @ 1550 nm
600m @ 1300 nm
Numerical Aperture 0.275 +/- 0.015 0.200 +/- 0.015 0.140 +/- 0.015
9.2 +/- 0.4 µm @ 1310
Mode Field Diameter n/a
nm
10.4 +/- 0.5 µm @ 1550 nm
1302-1322
Zero Dispersion Wavelength n/a
0.86 ps/(km*nm^2)
Zero Dispersion Slope n/a
Cable Cutoff Wavelength n/a
Total Dispersion
n/a
\[ps/(nm*km)\]
Cabled Polarization Mode Dispersion n/a
Water Peak Attenuation n/a
1383 +/- 3 nm
2.05 TIGHT BUFFER - INDOOR/OUTDOOR OPTICAL FIBER
A.Provide tight buffer type ruggedized fiber optic cable for all outdoor and indoor/outdoor
segments. Cable shall meet UL OFNR specifications and not require transition splicing upon
building entry in order to meet fire codes.
B.Cable shall be flame-retardant, UV stabilized, fully water blocked for use in indoor/outdoor
applications. Cable shall be suitable for installation in duct, aerial, cable tray, and riser
environments.
C.Optical fibers and subgroup cables shall be placed inside acrylate fiber coating and tight-
buffer, covered with a color-coded elastomeric subcable jacket.
D.The cable core shall contain a water-blocking material. The water-blocking material shall
be non-nutritive to fungus, electrically non-conductive, and homogenous. It shall also be
free from dirt and foreign matter and shall be readily removable with conventional non-
toxic solvents. Cable shall contain water-blocking threads between tubes. The cable shall
contain at least one ripcord under the sheath for easy sheath removal.
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E.Tensile strength shall be provided by a combination of high tensile strength dielectric yarns.
The high tensile strength dielectric yarns shall be helically stranded evenly around the cable
core.
F.All dielectric cables (with no armoring) shall be sheathed with medium density
polyethylene (MDPE). The minimum normal jacket thickness shall be 1.4 mm. Jacketing
material shall be applied directly over the tensile strength members and water-blocking
material. The polyethylene shall contain carbon black to provide ultraviolet light protection
and shall not promote the growth of fungus.
G.Armored cables shall have armor composed of a corrugated steel tape, plastic-coated on
both sides for corrosion resistance, and shall be applied with on an overlapping seam with
the corrugations in register. All armor splices shall be recoated with plastic to maintain the
armor’s corrosion resistance. The outer jacket shall be applied over the corrugated steel
tape armor. The outer jacket shall be a medium density polyethylene with a minimum
nominal jacket thickness of 1.25 mm. The polyethylene shall contain carbon black to
provide ultraviolet light protection and shall not promote the growth of fungus.
H.Tight buffer fiber optic cable type shall be selected from and meet or exceed the following
requirements:.
1.Fiber Type : OM1 62.5 µm Legacy MultiMode
2.Fiber Count : 12 strands
3.Tight Buffer
4.Outer Jacket Material: Flame retardant, UV-Resistant
5.Outer Jacket Color: Black
6.Maximum Attenuation: 3.4 db/km @ 850 nm and 1.0 db/km @1300 nm
7.Minimum Overfilled Launch (OFL) Bandwidth (MHz*km): 200 @ 850 nm and 500
@1300 nm
8.Minimum Effective Modal Bandwidth (EMB) (MHz*km): 220 @ 850
9.All-dielectric
10.Water blocking
11.Operating Temperature: -40° to +70°C
12.Maximum Nominal Outside Diameter of 0.3 inch
13.Manufacturer warranty.
2.06CABLE CONSTRUCTION
A.Mechanical Specifications
1.Each optical fiber shall be proof tested by the fiber manufacturer at a minimum of 100
kpsi (0.7 GN/m2).
2.The fiber shall be coated with a dual layer acrylate protective coating. The coating shall
be in physical contact with the cladding surface.
3.Crush Resistance = 10 kN/m (685 lb./ft.) length of cable.
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4.Cable Outside Diameter < 0.30 inch.
5.Weight per 1000 linear foot < 30 lbs.
6.Maximum Tensile Strength
a.Short-Term: 675 N (150 lbf).
b.Long-Term: 200 N (45 lbf).
7.Minimum Bending Radius
a.Installation, 15X Diameter.
b.Static, 12X Diameter.
8.Temperature (Operational)
a.-40 degrees C (-40 degrees F) to +70 degrees C (158 degrees F).
b.Continuous operation without cracking or becoming brittle.
9.Temperature (Installation)
a.0 degrees C (32 degrees F) to +60 degrees C (140 degrees F) on reel.
b.Humidity @ 0 to 100 percent, inclusive.
B.Riser Cables
1.Riser cables up to 24 fibers:
a.In cables with more than one fiber, the fibers shall be stranded around a dielectric
member and surrounded by layered aramid yarns. The aramid yarns shall serve as
the tensile strength member of the cable. A ripcord may be applied between the
aramid yarns and the outer jacket to facilitate jacket removal. The outer jacket
shall be extruded over the aramid yarns for physical and environmental
protection.
2.Riser cables with more than 24 fibers:
a.The buffered fibers shall be grouped into six fiber subunits. In each subunit, the
individual fibers shall be stranded around a dielectric central member and
surrounded by layered aramid yarns. A ripcord shall be incorporated in the
subunit design to facilitate access to the individual fibers. The subunit jacket shall
be extruded over the aramid yarns for additional physical and environmental
protection. The subunits shall be stranded around a dielectric central member. A
ripcord shall be inserted beneath the outer jacket to facilitate jacket removal.
The outer jacket shall be extruded around the units for physical and
environmental protection.
C.Plenum Cables
1.Plenum cables up to 24 fibers:
a.The fibers shall be stranded around a dielectric member and surrounded by
layered aramid yarns. The aramid yarns shall serve as the tensile strength
member of the cable. A ripcord may be applied between the aramid yarns and
the outer jacket to facilitate jacket removal. The outer jacket shall be extruded
over the aramid yarns for physical and environmental protection.
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2.Plenum cables with 24 to 72 fibers:
a.The buffered fibers shall be grouped into six fiber subunits. In each subunit, the
individual fibers shall be stranded around a dielectric central member and
surrounded by layered aramid yarns. A ripcord shall be incorporated in the
subunit design to facilitate access to the individual fibers. The subunit jacket shall
be extruded over the aramid yarns for additional physical and environmental
protection. The subunits shall be stranded around a dielectric central member. A
ripcord shall be inserted beneath the outer jacket to facilitate jacket removal.
The outer jacket shall be extruded around the units for physical and
environmental protection.
3.Plenum cables with more than 72 fibers:
a.The buffered fibers shall be grouped into twelve fiber subunits. In each subunit,
the individual fibers shall be stranded around a dielectric central member and
surrounded by layered aramid yarns. A ripcord shall be incorporated in the
subunit design to facilitate access to the individual fibers. The subunit jacket shall
be extruded over the aramid yarns for additional physical and environmental
protection. The subunits shall be stranded around a dielectric central member. A
ripcord shall be inserted beneath the outer jacket to facilitate jacket removal.
The outer jacket shall be extruded around the units for physical and
environmental protection.
D.The strength member shall be a high modulus aramid yarn. The aramid yarns shall be
helically stranded around the buffered fibers. Non-toxic, non-irritant talc shall be applied
to the yarn to allow the yarns to be easily separated from the fibers and the jacket.
E.Cable Jacket
1.The jacket shall be continuous, free from pinholes, splits, blisters, or other
imperfections. The jacket shall have a consistent, uniform thickness; jackets extruded
under high pressure are not acceptable. The jacket shall be smooth, as is consistent
with the best commercial practice. The jacket shall provide the cable with a tough,
flexible, protective coating, able to withstand the stresses expected in normal
installation and service.
2.The cable and subunit jacket color shall be orange for cables containing multimode
fibers.
3.The cable and subunit jacket color shall be yellow for cables containing single-mode
fibers.
4.For cables with more than two fibers, the cable jacket shall be designed for easy
removal without damage to the optical fibers by incorporating a ripcord under each
cable jacket. Non-toxic, non-irritant talc shall be applied to the aramid yarns to allow
the yarns to be easily separated from the fibers and the jacket.
5.The nominal thickness of the cable outer jacket shall be sufficient to provide adequate
cable protection while meeting the mechanical, flammability, low smoke, and
environmental test requirements of this document over the life of the cable.
F.The cable shall be all-dielectric.
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2.07CABLE IDENTIFICATION
A.The individual fibers shall be color coded for identification according to EIA/TIA-598, “Color
Coding of Fiber Optic Cables.” The coloring material shall be stable over the temperature
range of the cable, shall not be susceptible to migration, and shall not affect the
transmission characteristics of the optical fibers. Color coded buffered fibers shall not
adhere to one another. When fibers are grouped into individual units, each unit shall be
numbered in the unit jacket for identification. The number shall be repeated at regular
intervals.
B.Cable jackets shall be marked with manufacturers’ name, sequential meter or foot
markings, the year of manufacture, and a telecommunication handset symbol, as required
by Section 350G of the National Electrical Safety Code (NESC). The actual length of the
cable shall be within 1 percent of the length markings. The marking shall be in contrasting
color with the cable jacket. The height of the marking shall be approximately 2.5 mm.
C.Bulk cables shall be individually labeled at each end with a designated cable number or tag,
or at minimum a printed label notating the to/from location designation.
D.Fiber patch panels shall have printed termination schedule detailing each termination panel
and each port. Termination panel labels shall be labeled corresponding to the bulk cable
assignment, while port terminations labeled according to device terminations.
2.08CABLE FACTORY TESTING REQUIREMENTS
A.Fiber cables shall be factory tested in accordance with the following industry standard (EIA-
455) tests:
1.FOTP-41, Compressive Loading Resistance Test.
2.FOTP-104, Fiber Optic Cable Cyclic Flexing Test.
3.FOTP-25, Repeated Impact Testing.
4.FOTP-33, Fiber Optic Cable Tensile Loading and Bending Test.
5.FOTP-85, Fiber Optic Cable Twist Test.
6.FOTP-181, Lightning Damage Susceptibility Test.
7.FOTP-3, Procedure to Measure Temperature Cycling Effects on Optical Fibers, Cables,
and other Passive Fiber Optic Components.
8.FOTP-82, Fluid Penetration Test for Fluid-Blocked Fiber Optic Cable.
9.FOTP-37, Low or High Temperature Bend Test for Fiber Optic Cable.
10.FOTP-98, External Freezing Test.
11.FOTP-27, Fiber Diameter Measurements.
12.FOTP-28, Measurement of Dynamic Tensile Strength.
13.FOTP-34, Interconnection Device Insertion Loss Test.
14.FOTP-89, Cable Jacket Elongation and Tensile Strength Test.
B.Cable shall be tested on-reel prior to shipment.
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C.End to end loss shall be recorded for each fiber at 1,310 nm; 1,550 nm; and 1,625 nm (for
Single-mode). End to end loss shall be recorded for each multi-mode fiber at 850 nm and
1,300 nm.
D.OTDR with hard copy record shall be provided for each single mode fiber, at 1,300 nm;
1,550 nm; and 1,625 nm. OTDR with hard copy record shall be provided for each multi-
mode fiber at 850 nm and 1,300 nm.
E.Polarized Modal Dispersion (PMD) for each single mode fiber shall be measured using a
PMD analyzer and polarized light source.
F.Chromatic optical dispersion shall be tested for each single mode fiber.
G.Certified copies of tests results shall be submitted to the Engineer as described in these
specifications 14 days after completion of each test. The Contractor shall submit laboratory
test reports on representative samples of similar cable design to demonstrate compliance
prior to cable installation.
2.09FIBER CONNECTORS AND PASSIVE COMPONENTS
A.Fiber Connectors
1.The fiber optic communications system shall utilize LC style connectors for all fiber
optic connections. Other style connectors will be acceptable only if LC style connectors
are not compatible with the equipment being provided. The connectors shall be
designed for use with the fiber optic cable size and grade in which it is to be installed.
Each connector shall cause a maximum signal attenuation of 1.0 dB.
2.When available network products use connectors other than LC-type, optical patch
cables shall be provided with the corresponding non-LC-type connector on the
equipment end, and the LC-type connector on the distribution panel end. Example: ST-
to-LC patch cord.
3.Optical parameters of the connectors shall meet the requirements of EIA/TIA-568.
4.Field-Installed Connectors shall be type LC compatible, SC or ST design with ceramic or
polymer ferrule and strain relief boot. The connector installation shall not require the
use of epoxies, adhesives or ovens. The connector shall contain a mechanical splice
and have a tool kit available to aid in assembly. The installation tools used to terminate
the connector shall be able to terminate other small-form-factor and single-fiber
UniCam connector designs. The connector shall not require end-face polishing in the
field. The connector shall have a factory polished optical fiber stub in the connector
ferrule that is bonded in the ferrule micro hole. Ferrule material shall be available in
ceramic or polymer. Connector specifications shall be as follows:
a.Insertion loss (typical): 0.3 dB.
b.Durability (mating cycles): 500 (minimum).
c.Repeatability: Less than 0.2 dB.
d.Operating Temperature: 0 to plus 60 degrees C.
5.After termination with connectors, the fiber ends must be visually inspected at a
magnification of not less than 100 power for multimode and 200x for single mode to
check for cracks or pits in the endface of the fiber.
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6.Connectors shall have a maximum allowable connection loss of 0.3 dB per mated pair,
as measured per EIA-455-34. No index-matching gel is to be used; dry interfaces only.
7.Each connector shall be of the industry standard ST type compatible; designed for
single-mode and multimode tolerances; shall meet or exceed the applicable provisions
of EIA-455-5, 455-2A, and 455-34; and shall be capable of 100 repeated ratings with a
maximum loss increase of 0.1 dB. Connectors shall incorporate a key-way design and
shall have a Zirconia ceramic ferrule. Connector bodies and couplings shall be made of
corrosion-resistant and oxidation-resistant materials such as nickel-plated zinc,
designed to operate in humid environments without degradation of surface finishes.
Connectors shall be capable of operating in a range of -40 to 80 degrees C.
8.Manufacturers
a.Corning Cable Systems.
b.AMP Netconnect.
c.3M Telecom Systems Group.
B.Fiber Slack Enclosures
1.Enclosures shall be NEMA 4X, 316 stainless steel for outdoor installations; and NEMA
12, painted steel or fiberglass for indoor installations. Enclosures shall include hinged
cover and securing mechanism.
2.Enclosures shall be sized for 100 feet of cable slack.
3.Hardware
a.Hooks shall be provided to hold cable slack, with coils of required bend radius.
b.Velcro ties to restrain cable shall be utilized.
C.Fan-Out Kits
1.Individual fibers within a loose tube cable with 250 µm coated fibers shall use a fan-
out kit to maintain flexibility and ease of handling fibers within a termination cabinet.
Fan-out kits shall be installed in the patch panel enclosures to transition the loose tube
fibers to ruggedized tight-buffered fiber pigtail cables. Optical fusion splices shall
connect the loose tube fibers to the tight-buffered pigtail cables. The optical splice
loss shall comply with the specifications for optical splices. Splice protection sleeves
shall be employed on all splices to protect the splices.
2.The tight-buffered pigtails shall be factory-preconnectorized with STTM connectors as
specified.
2.10FIBER OPTIC PATCH CORDS AND PIGTAILS
A.Patch cords and pigtails shall be cable assemblies consisting of flexible optical fiber cable
with LC (or SC/ST, if required) compatible connectors. Patch cords shall be complete factory
fabricated assemblies from manufacturer's standard product lines. Fiber optic jumper
cables shall meet the following requirements.
B.Patch Cord Assemblies
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1.The cable construction shall allow a small bend radius for installation in space-
constrained areas. The cable shall contain a dielectric strength member and a
protective outer jacket.
2.The Patch Cord shall comply with the requirements of TIA-568-B.3.
C.Connectors
1.One LC-type (or SC/ST-type, if required) duplex connector shall be provided on Patch
cords.
2.One LC-type (or SC/ST-type, if required) simplex connector shall be provided on
pigtails, with the other end prepared for splicing.
3.LC-type (or SC/ST-type, if required) connectors used for single-mode fiber will be
colored yellow. ST-type (or SC/ST-type, if required) connectors used for multi-mode
fiber will be colored orange.
D.Fiber Cable
1.Patch cords and pigtails shall utilize a two-fiber zip-cord type jacketed cable, in lengths
required to meet minimum bend radius while connected and routed through cable
management hardware but no less than 6 feet in length. The cable jacket color shall be
orange for multi-mode and yellow for single mode cable. The fiber core size shall also
be identified on the outer jacket.
2.The optical fiber shall meet the same characteristic requirements of the distribution
panel terminated cable to which it mates.
3.Tensile strength of the jacketed cable shall be greater than or equal to 20 lbs.
E.Pigtails with LC-type (or SC/ST-type, if required) connector on one end and the other end
bare fiber, 3 meters length, shall be by Corning Cable Systems or approved equal.
2.11FIBER OPTIC TERMINATION PATCH PANELS
A.General
1.Patch panels shall be suitable for wall mounting, comprised of internal mounting plate,
cable holders, slack cable take up/organizer blocks, patch block with connectors, and
ground lugs as indicated. Panels shall be NEMA 4X, 316 stainless steel for outdoor
installations; and NEMA 12, painted steel, polycarbonate or fiberglass for indoor
installations. Patch panels shall be suitable for multimode and single mode systems
operation. Patch panels shall be suitable for ST, SC, or LC connectors. The patch
panels shall be sized to handle the number of fibers as required. All fibers shall be
terminated in the patch panel.
2.Where shown on the plans or in the related specification Sections, the fiber optic cable
shall terminate inside a communications cabinet on a termination patch panel. All
fiber sub-cables within the exposed buffer tube shall be terminated with fan-out kits
with preconnectorized pigtails. The patch panel shall have a fiber capacity equal to the
total number of fibers (connected and spare) for all cables to be connected.
3.Unused buffer tubes shall be uncut and looped within the patch panel for continuous
routing of the fiber buffer tube within the cable assembly.
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4.Patch panels shall be designed for either rack mounting on a standard equipment rack
or housed in an enclosure for direct wall mounting. The patch panel shall contain ST
or SC type bayonets or LC couplings. All unused couplings shall have protective dust
covers. All panels shall be furnished with locking doors.
5.Factory-terminated, tight-buffered, aramid-reinforced fiber optic jumper assemblies or
interconnect cables, standard 3.0 mm O.D., shall connect the optical cable
terminations to the patch panel couplings.
6.The termination patch panel shall be equipped with a suitable means for routing and
securing of cables, and shall provide a suitable means of protection for the mounted
fiber connectors to prevent damage to fibers and connectors during all regular
operation and maintenance functions. All cables shall be provided with strain relief.
Bend diameters on cable fibers and jumpers must be greater than four inches at all
times to ensure optical and mechanical integrity of the optical fibers.
7.Termination panels shall be equipped with splice trays (where applicable) and holders
for pigtail and through fiber splicing.
8.Termination panels shall be provided with all hardware, options, and accessories to
provide for a complete installation of the fiber optic system.
9.Panels shall be as manufactured by Corning Cable Systems LANscape or equal.
B.Rack Mount Fiber Distribution Center (FDC) Splice Housing
1.A rack-mountable Fiber Distribution Center splice housing shall be provided for pigtail
splicing and through fiber splicing equipment.
2.The splice housing shall be compatible with the FDC for interconnection of the splicing
equipment with the fiber cable management, termination, and distribution rack
equipment.
3.Splice trays shall be provided for pigtail splicing.
4.The splice housing shall be sized and equipped with sufficient capacity to terminate
and feed through all required fiber cable, plus an additional 20 percent.
5.Provide one spare splice tray.
6.Splice housing shall be Corning Cable Systems LANscape CSH series.
C.Rack Mount Fiber Distribution Center (FDC)
1.The Fiber/Network equipment rack shall be supplied with two rack-mountable Fiber
Distribution Centers (FDCs) capable of 48 LC fiber termination points each. The
connector center shall be 19-inch rack-mountable and provide for internal fan-out,
splicing, and connection of the fiber optic cable to front panel LC connection patch
panel.
2.The FDC shall provide backbone and intermediate connects and cable strain relief for a
maximum of five fiber cable systems. The front shall be swing open construction with
keyed latch mechanism.
3.The FDC shall be compatible for interconnection with the FDC Splice Housing and
provide space and support the addition of fiber cable splice trays for future cable
connection and termination.
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4.The Fiber Connection Center shall be Corning Cable Systems LANscape CCH series.
D.Wall/Panel Mount Fiber Distribution Center (WDC)
1.The field-mounted fiber termination enclosures shall be supplied with a Wall Mount
Fiber Distribution Center (WDC) capable of 48 LC fiber termination points. The
distribution center shall be panel-mounted and provide for internal fan-out, splicing,
and connection of the fiber optic cable to the patch panel assemblies.
2.Splice trays shall be provided for pigtail splicing. The WDC shall be provided with pass-
thru splice trays for continuation of the fiber cable system to additional sites.
3.Provide one spare splice tray.
4.The WDC shall provide space and support the addition of future fiber cable splice
trays.
5.The Wall Mount Fiber Distribution Center shall be Corning Cable Systems LANscape
(WCH) series.
E.Single Pane Housing / Termination Panel
1.Single panel housing shall meet or exceed the following minimum requirements:
a.Holds 2 CCH connector panels (6 strands each)
b.Can be used for splice management, cross-connect or both for up to 12 fibers
with LC connectors.
c.Provided top and bottom cable entry grommets allow for midspan access and
environmental sealing.
d.Dimensions of 6.3” H x 5.5” W x 2.0” D.
2.All connectors for the termination of the fiber optic cable shall be duplex LC
connectors.
3.The Single Panel Termination Panel shall be Corning Cable Systems LANscape (SPH)
series.
2.12INNERDUCT
A.Inner-ducts shall be constructed of flame-retardant PVC or FCP material and shall meet the
following flammability requirements:
1.OSP, inside building horizontal (no more than 50 feet from the point of entrance), and
inside building riser inner-duct shall meet the UL 2024 (raceways) flame test.
2.Inner-duct installed in any air plenum environment shall meet NFPA 262 (2002).
3.Inner-duct shall have smooth exterior and interior wall, and semi-rigid construction.
4.Inside building horizontal and riser inner ducts shall be flexible and corrugated type.
5.Inner-ducts shall be compatible with the fiber optic cable that is being installed.
6.Internal diameter shall be a minimum of 1 inch.
7.Couplers, if used, shall not reduce the inside diameter of the inner-duct.
8.All unused inner-duct shall be preinstalled with lubricated pull tape or line.
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9.Inner-duct used to house single-mode fiber cable will be colored yellow. Inner-duct
used to house multi-mode fiber cable will be colored orange.
2.13WIRE PULLING LUBRICANT
A.Wire Pulling Lubricant shall have the following characteristics:
B.Polymer-based.
C.Average Coefficient of Friction: 0.055.
D.Temperature Range: -28 degrees F to 180 degrees F.
E.Compatible with all cable types.
2.14AIR BLOWN FIBER OPTIC SYSTEMS
A.General Fiber Specifications
1.All fibers in the bundle must be usable and meet required specifications.
2.Each optical fiber shall be sufficiently free of surface imperfections and inclusions to
meet the optical, mechanical, and environmental requirements of this specification.
3.Each optical fiber shall consist of high-grade silica, doped as necessary to achieve the
required light guiding properties. The fiber shall be a matched clad, step-index design.
4.The fiber shall be coated with a dual layer of ultra-violet cured acrylate resin
protective coating. The coating shall be in physical contact with the cladding surface.
5.The attenuation specification shall be a maximum value for each bundled fiber at 23 ±
5 degrees C on the original shipping reel.
6.The fibers will be contained in a soft inner acrylate layer, an outer harder layer which
protects the fibers from damage, and a low friction layer that assists in improved
blowing distance, typically in excess of 1000 meters.
7.Fiber bundle units will be available in a range of lengths up to 6000 meters.
B.The main optical, geometrical, and physical characteristics will be compliant with ITU-T Rec.
G.652 C/D for Low Water-peak Single-mode Fiber.
1.Geometry Standards
a.Cladding Diameter (pm) = 125.0 ± 0.7.
b.Core Concentricity (pm) 0.84.
c.Cladding Non-Circularity 1.0 percent.
d.Mode Field Diameter @ 1310 nm (pm) = 8.8-9.6.
e.Effective Area, Aeff (Characterized): (pm2) = 72.
f.Coating Concentricity (pm) 12.0.
2.Optical Standards
a.Cabled Fiber Attenuation @ 1310 nm (dB/km) 0.38.
b.Cabled Fiber Attenuation @ 1550 nm (dB/km) 0.26.
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c.Point discontinuity @ 1550 nm (dB) 0.1.
d.Attenuation at 1383 nm (dB/km) 0.35.
e.Attenuation Uniformity over 2 km (dB/km) 0.05.
2
f.Dispersion Slope @ 0.089 (ps/nm/km).
g.Cable Cutoff Wavelength (Accf) (nm) 1480.
h.Total Dispersion (ps/nm/km)
1)3.5 @ 1330 nm
2)18.0 @ 1550 nm
i.Cabled Polarization Mode Dispersion (ps/km) 0.5.
j.Water Peak Attenuation @ 1383+/- 3 nm; 2.1 dB/km.
C.Environmental and Mechanical Tests and Specifications
1.Operation/Storage -10 degrees C to +60 degrees C yields 0.07 db/km @ 1310 and 1550
nm.
2.Condensation tested -10 degrees C to +65 degrees C @ 93 percent RH for 24 hours x
10 yields 0.07 db/km @ 1310 and 1550 nm.
3.Water immersion test at +20 degrees C for 2000 hours yields 0.07 db/km @ 1310 and
1550 nm.
4.Cold tested at -20 degrees C for 96 hours yields 0.07 db/km @ 1310 and 1550 nm.
5.Each optical fiber shall be proof tested by the fiber manufacturer at a minimum of 100
kpsi (0.7 GN/m2).
6.Bend tested @ 40 mm (2 and 4 fibers) or 60 mm (8 fibers) yields no change in
attenuation after test.
7.Aged Bend tested (60 degrees C for 1000 hours) @ 40 mm (2 and 4 fibers) or 60 mm (8
fibers) yields no change in attenuation after test.
8.Tensile Strength tested @ 1W N (9.81x mass of 1 km) @ 0.4 percent (maximum fiber
strain).
9.12 Fiber Outside Diameter: 1.3 mm.
10.12 Fiber Weight: 1.5 g/m.
11.12 Fiber Blowing Distance: 1000 m typical.
12.12 Fiber Breakout: 8 minutes typical
D.Technical Specifications
1.Air blown fiber tube installed in existing duct, conduit, or inside buildings will meet the
following criteria:
a.Tubes will be low friction HDPE in small diameters for air blown fiber tubes up to
12 fibers per tube.
b.Each 12-fiber primary tube will have an outside diameter (O.D.) of 5 mm.
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2.A secondary HDPE fiber duct will house multiple primary 5 mm fiber tubes with the
following specifications:
Fiber Capacity O.D (mm) Nominal Weight (g/m)
2 x 5mm tubes (24 fibers) 12.8-13.8 78
4 x 5mm tubes (48 fibers) 14.8-16.5 116
7 x 5mm tubes (84 fibers) 17.8-19.4 159
12x5mm tubes (144 fibers) 23.0-24.8 234
24x5mm tubes (288 fibers) 32.3-34.4 422
3.The secondary multi-tube duct will include a moisture barrier aluminum shield and
outer polyethylene sheath. A ripcord will be included for easy cable access. The
following shall apply to all secondary multi-tube assemblies:
a.Maximum tensile strength (N) = 1W; tested in accordance with IEC 60794-1-2
Method E1. There will be no permanent deformation of the primary or secondary
assemblies after an applied load of 1.0 (spec.weight kg/km) N at 20 mm/minute.
b.The Crush Rating (KN) = 1; tested in accordance with IEC 60794-1-2 Method E3.
There will be no permanent deformation of the primary assemblies greater than
0.5 mm after a maintained load of 1KN for 1 minute.
c.The minimum bend radius (mm) = 12 x diameter.
d.Stress crack resistance will be tested in accordance with BS6469 Section 99.1 with
chemical Caflon CF30.
e.Individual fiber tubes will be opaque or translucent for fiber visibility.
f.Secondary multi-tube duct will be available on drums up to 3000m in length.
4.Air blown fiber tube installed outside, direct bury, will meet the following criteria:
a.Tubes will be low friction HDPE in small diameters for air blown primary fiber
tubes up to 12 fibers per tube.
b.Each 12-fiber primary tube will have an outside diameter (O.D.) of 5 mm.
5.A secondary HDPE fiber duct will house multiple primary 5 mm fiber tubes with the
following specifications:
Fiber CapacityO.D (mm)Nominal Weight (g/m)
2 x 5mm tubes (24 fibers)11.0-13.2142
4 x 5mm tubes (48 fibers)18.1-22.3204
7 x 5mm tubes (84 fibers)21.6-23.3278
12x5mm tubes (144 fibers)28.2-29.5479
24x5mm tubes (288 fibers)37.8-39-1755
6.The secondary multi-tube duct will include a moisture barrier aluminum shield and
two heavy duty outer polyethylene sheath layers. A ripcord will be included for easy
cable access. The following shall apply to all secondary multi-tube assemblies:
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a.Maximum tensile strength (N) = 1W; tested in accordance with IEC 60794-1-2
Method E1. There will be no permanent deformation of the primary or secondary
assemblies after an applied load of 1.0 (spec.weight kg/km) N at 20 mm/minute.
b.The Crush Rating (KN) = 2; tested in accordance with IEC 60794-1-2 Method E3.
There will be no permanent deformation of the primary assemblies greater than
0.5 mm after a maintained load of 2 KN for 1 minute.
c.The minimum bend radius (mm) = 12 x diameter.
d.Stress crack resistance will be tested in accordance with BS6469 Section 99.1 with
chemical Caflon CF30.
e.Individual fiber tubes will be opaque or translucent for fiber visibility.
f.Secondary multi-tube duct will be available on drums up to 3000 m in length.
7.Air blown fiber tube installed outside, direct bury, armored, will meet the following
criteria:
a.Tubes will be low friction HDPE in small diameters for air blown primary fiber
tubes up to 12 fibers per tube.
b.Each 12-fiber primary tube will have an outside diameter (0/D) of 5 mm.
c.A secondary HDPE fiber duct will house multiple primary 5 mm fiber tubes with
the following specifications:
Fiber Capacity O.D (mm) Nominal Wt (g/m)
2 x 5mm tubes (24 fibers) 11.9 353
4 x 5mm tubes (48 fibers) 18.9 536
7 x 5mm tubes (84 fibers) 21.9 630
12x5mm tubes (144 fibers) 27.1 756
24x5mm tubes (288 fibers) 36.5 1071
8.The secondary multi-tube duct will include an inner polyethylene sheath layer, a
corrugated armored layer, and an outer heavy duty polyethylene sheath layer. A
ripcord will be included for easy cable access. The following shall apply to all secondary
multi-tube assemblies:
a.Maximum tensile strength (N) = 1W; tested in accordance with IEC 60794-1-2
Method E1. There will be no permanent deformation of the primary or secondary
assemblies after an applied load of 1.0 (spec.weight kg/km) N at 20 mm/minute.
b.The Crush Rating (KN) = 2; tested in accordance with IEC 60794-1-2 Method E3.
There will be no permanent deformation of the primary assemblies greater than
0.5 mm after a maintained load of 3KN for 1 minute.
c.The minimum bend radius (mm) = 12 x diameter.
d.Stress crack resistance will be tested in accordance with BS6469 Section 99.1 with
chemical Caflon CF30.
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e.Individual fiber tubes will be opaque or translucent for fiber visibility.
f.Secondary multi-tube duct will be available on drums up to 3000m in length.
3.00EXECUTION
3.01GENERAL
A.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
B.Provide all material, equipment, and labor to test and integrate the fiber optic system as
indicated and as specified.
C.Installation shall comply with EIA/TIA Standards 568 and 569. Outside plant hardware and
installation equipment should follow manufacturer’s recommendations.
D.Fiber optic cables shall be continuous from component to component. Intermediate fiber
splices shall not be allowed.
E.Notify the Engineer in writing at least 48 hours in advance of installation of each section of
optical cable.
F.The Contractor shall take care to ensure that the cable collects a minimal amount of dust
and/or dirt during installation.
G.Cable shall be installed in accordance with the National Electrical Safety Code (NESC)
requirements and the local electric utility requirements.
H.Field verify the routing of fiber optic cable before starting work.
I.All strands of fiber shall be terminated.
J.The bend radius for fiber-optic backbone cable shall not be less than the manufacturer’s
recommended minimum bend radius.
K.The tensile load for fiber-optic backbone cable shall not exceed the manufacturer’s
recommended maximum tensile load.
L.Inspect all fiber optic cables before and after installation.
M.Faulty fiber optic cables shall be removed and replaced at no additional cost to the Owner.
N.Terminate both ends of all cables in a separate fiber optic termination enclosure unless
otherwise shown on Contract Drawings.
O.All below grade fiber optic cables shall be installed within a minimum 2” Schedule 80 PVC
Conduit. A #10 AWG trace wire shall be installed above the conduit.
3.02IDENTIFICATION
A.Fiber paring and termination orders throughout the network shall follow the TIA/EIA color
conventions for fiber conductors.
1.Fiber 1 – Blue
2.Fiber 2 – Orange
3.Fiber 3 – Green
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4.Fiber 4 – Brown
5.Fiber 5 – Slate
6.Fiber 6 – White
7.Fiber 7 – Red
8.Fiber 8 – Black
9.Fiber 9 – Yellow
10.Fiber 10 – Violet
11.Fiber 11 – Rose
12.Fiber 12 – Aqua
B.Label each termination point. Type written termination schedules shall be provided at each
patch panel identifying all port terminations and bulk cable “to/from” information for each
bulk cable segment.
C.Label each cable, buffer tube, and fiber with permanent waterproof typewritten tags.
3.03INSTALLATION
A.The OWNER reserves the right to relocate enclosures within 30 feet of the locations
identified in the Contract Drawings at no additional cost to the OWNER
B.All optical cable installation shall be accomplished in accordance with the approved plan.
1.Follow the cable manufacturer's recommendations. Fiber optic cable is often custom
designed for the installation and the manufacturer may have specific instructions on
its installation.
2.Check the cable length to make sure the cable being pulled is long enough for the run
to prevent having to splice fiber and provide special protection for the splices.
3.Try to complete the installation in one pull. Prior to any installation, assess the route
carefully to determine the methods of installation and obstacles likely to be
encountered.
C.All horizontal and backbone LAN fiber optic cable shall be installed in inner-duct. Outside
the Plant fiber optic cable shall be installed in inner-duct at locations outside of the wayside
trough as indicated in the Contract Drawings, through manholes, and through duct bank
conduits. All duct bank four inch communications conduits serving fiber optic cable shall
contain four 1 inch inner-ducts each. No more than one Outside the Plant fiber optic cable
shall be installed in a single inner-duct. The inner-duct shall be installed without coils or
twists.
D.Pull locations shall be selected to protect the cable on the reel and in slack loops. Be
responsible for protecting cable after working hours where cable installation is not
completed during a single shift. Cables damaged due to Contractor's negligence while
installing cable shall be replaced.
E.Pull lengths shall be designed to allow a 20 percent margin in cable tensile strength. Do not
exceed the lesser of 80 percent of the cable's maximum tensile rating or 600 lbs. during
installation. No residual tension shall remain on the cable after installation except that due
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to the cable's weight in the vertical rise. Wire Pulling Lubricant shall be used to reduce
tension on the cable during the installation process.
1.Cable manufacturers install special strength members, usually aramid yarn, for pulling.
Fiber optic cable should only be pulled by these strength members. Any other method
may put stress on the fibers and harm them.
2.Swivel pulling eyes should be used to attach the pulling rope or tape to the cable to
prevent cable twisting during the pull.
3.Cables should not be pulled by the jacket unless it is specifically approved by the cable
manufacturers and an approved cable grip is used.
4.Tight buffer cable can be pulled by the jacket in premises applications if a large (~40
cm, 8 inch) spool is used as a pulling mandrel. Wrap the cable around the spool 5 times
and hold gently when pulling.
5.On long runs (up to approximately 3 miles or 5 kilometers), use proper lubricants and
make sure they are compatible with the cable jacket. If possible, use an automated
puller with tension control and/or a breakaway pulling eye. On very long runs (farther
than approximately 2.5 miles or 4 kilometers), pull from the middle out.
F.If a winch or pulling machine is used during installation, a dynamometer shall be used to
monitor the tension on the cable. The dynamometer shall be certified as calibrated and
shall hold the peak value of the cable pull. The peak value shall be recorded and forwarded
to the Engineer as part of the installation test data submittals.
G.The maximum vertical rise shall be defined as the distance over which the cable is self-
supporting. Cable strain relief shall be used at the top of each vertical rise and no less than
every time that 80 percent of vertical rise rating of the cable is exceeded.
H.Drop vertical cables down rather than pulling them up whenever possible. Support cables
at frequent intervals to prevent excess stress on the jacket. Support can be provided by
cable ties (tightened snugly, not tightly enough to deform the cable jacket) or Kellems grips.
Use a minimum of two feet of service loops to assist in gripping the cable for support and
provide cable for future repairs or rerouting.
I.Cable Ties
1.Fiber optic cables, like all communications cables, are sensitive to compressive or
crushing loads. Cable ties used with many cables, especially when tightened with an
installation tool, are harmful to fiber optic cables, causing attenuation and potential
fiber breakage. When used, cable ties should be hand tightened to be snug but loose
enough to be moved along the cable by hand. Then the excess length of the tie should
be cut off to prevent future tightening.
2.Hook-and-loop fastener ties are preferred for fiber optic cables, as they cannot apply
crush loads sufficient to harm the cable.
J.Do not exceed the cable's minimum bend radius for cable under tension or long term
installation/storage. Fiber optic cable can be broken when kinked or bent too tightly,
especially during pulling. If no specific recommendations are available from the cable
manufacturer, the cable should not be pulled over a bend radius smaller than 20 times the
cable diameter. After completion of the pull, the cable should not have any bend radius
smaller than 10 times the cable diameter.
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K.Do not twist the cable. Twisting the cable can stress the fibers. Tension on the cable and
pulling ropes can cause twisting. Use a swivel pulling eye to connect the pull rope to the
cable to prevent pulling tension causing twisting forces on the cable. Roll the cable off the
spool instead of spinning it off the spool end to prevent putting a twist in the cable for
every turn on the spool. When laying cable out for a long pull, use a "figure 8" on the
ground to prevent twisting. The “figure 8” puts a half twist in on one side of the 8 and takes
it out on the other, preventing twists.
L.Continuity of cable shall be maintained between termination or splice locations shown on
the Contract Drawings. Additional splices shall not be allowed without the prior written
Engineer approval.
M.All cable entrance openings in equipment enclosures, houses, rooms and junction boxes
shall be sealed with either a compression type fitting or pliable sealing compound after the
cable is in place. Sealing compounds for rooms, houses, walls, or other partitions shall be
fire retardant per ASTM E-814. Sealing compound shall be used to seal the area around
cable where the cable emerges from the end of a conduit, pipe, or duct bank. All spare
conduits shall be sealed or plugged in an Engineer approved manner.
N.Cable Racks, Trays, Conduit and Innerduct
1.Outside plant cables can be installed underground in conduit, inner-duct, or direct
buried depending on the cable type. Aerial cable installation may use cables lashed to
a support messenger cable or be self-supporting. Underwater cable installation must
follow manufacturer’s directions.
2.Premises cabling can be installed in cable trays, ladder racks, J-hooks, or other
appropriate support structures.
3.Building cables shall be installed inside plenum-rated inner-duct for enhanced
identification and protection.
3.04TERMINATION
A.Breakout Kits
1.Breakout kits shall be used to separate and protect individual fibers in a loose tube
cable for termination directly on the fibers.
B.Splice Enclosures
1.Provide splice closures for long cable runs outside, requiring connection of cable
segments. Splice closures shall be sized with adequate space for the number of fibers
in the cables and port locations appropriate for final mounting. Splice closures can be
sealed and buried in the ground, placed in a vault or suspended aerially. Outside plant
cables terminated in buildings may also need closures if they are terminated by
splicing on pre-terminated pigtails.
C.Splice Panels and Patch Panels
1.Terminate or splice distribution cables inside panels or boxes to protect the fibers
from damage. Boxes or panels may be rack- or wall-mounted and shall have locks to
prevent unauthorized entry.
D.Racks and Cabinets
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1.Enclosures for patch panels and splice panels are used to terminate and organize
cables. Use appropriate cable management hardware on the racks to route and
separate cables to minimize potential for damage and facilitate moves, additions, and
changes.
E.Slack in Fiber Slack Enclosures (FSEs) shall be carefully coiled in order to avoid violating the
short and long term minimum bend radius. Supply a minimum of 150 feet of slack at each
termination of the cable inside the FSE. Slack in Fiber Patch Panels (FOPPs) shall be
restrained and shall be sufficient for strain relief. Take care with all splicing and termination
hardware to maintain cable bend radiuses, prevent pinching or kinking of fibers and
separate fibers to allow for future restoration, moves or other work.
F.The central strength member of cable shall be attached to the FOPP. The outer jacket of
cable shall be attached to the FOPP with a cable clamp.
G.All fiber optic splices shall be fusion splices. Perform splicing at fiber slack enclosures only
for the purposes of passing an optical connection through a Communications House. Fusion
splicing shall be performed by qualified personnel utilizing a splicer equipped with Local
Injection and Detection (LID) to optimize splices. The loss across each spliced fiber shall be
less than or equal to 0.04 db.
H.All fiber optical terminations at buildings and wayside facilities shall be field or factory
terminated.
I.Notify the Engineer in writing at least one week in advance of terminating each section of
optical cable.
J.Where armored cable is utilized, the armor shall be grounded to the building ground bus at
one termination location.
3.05FIELD QUALITY CONTROL
A.Examine all connectors requiring polishing with a microscope for proper end finish, cracks,
scratches or dirt per FOTP-57.
B.Cable Plant Field Tests
1.Tests shall be performed after installation is complete.
2.One week advance notice to the Engineer shall be provided.
3.Optical attenuation from FOPP to FOPP shall be recorded.
4.Every fiber optic cabling link shall be tested in accordance with the field test
specifications defined by the TIA-568-B.3 (or by the required network application
standards), whichever is more demanding.
5.TIA-568 shall be used to define the passive cabling network, to include cable,
connectors, and splices (if present), between two optical fiber patch panels
(connecting hardware). This TIA document shall be used to describe all applicable link
segments. Tests shall include the representative connector performance at the
connecting hardware associated with the mating of patch cords but not the
performance of the connector at the interface with the test equipment.
6.All of the cabling links installed shall be tested and shall pass the requirements of the
standards mentioned in above. Any failing link shall be diagnosed and corrected prior
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to the system acceptance. The corrective action shall be followed with a new test to
prove that the corrected link meets the performance requirements. The final and
passing result of the tests for all links shall be provided in the test results
documentation in accordance with requirements listed below.
7.Trained technicians who have successfully attended a required training program and
have obtained a certificate, as proof thereof shall be used to execute the tests. These
certificates may have been issued by any of the following organizations or an
equivalent organization:
a.The manufacturer of the fiber optic cable and/or the fiber optic connectors.
b.The manufacturer of the test equipment used for the field certification.
c.Training organizations authorized by BiCSI (Building Industry Consulting Services
International), or by the ACP (Association of Cabling Professionals).
8.Field test instruments for multimode fiber cabling shall meet the requirements of TIA-
526-14. The light source shall meet the launch requirements of TIA-455-78. This launch
condition can be achieved either within the field test equipment or by use of an
external mandrel wrap (as described in clause 11 of TIA-568) with a Category 1 light
source. Field test instruments for single mode fiber cabling shall meet the
requirements of TIA-526-7.
9.The test instrument calibration date shall be within the calibration period
recommended by the vendor in order to achieve the vendor specified measurement
accuracy.
10.The fiber optic launch cables and adapters shall be of high quality and the cables shall
not show excessive wear resulting from repetitive coiling and storing of the test
instrument interface adapters.
11.The Pass or Fail condition for the link-under test is determined by the results of the
required individual tests. A Pass or Fail result for each parameter is determined by
comparing the measured values with the specified test limits for that parameter.
12.An Engineer representative shall be invited to perform field testing. The representative
shall be notified of the start date of the testing phase five business days before testing.
The Engineer's representative shall select up to 5 percent of the links installed. The
representative (or his authorized delegate) shall test these selected links and the
results are to be stored in accordance with the prescriptions in this Section. The results
obtained shall be compared to the data provided by the Contractor. If the sample
results differ in terms of the Pass/Fail determination, repeat testing of the affected link
under observation of the Engineer.
C.Cable Plant Performance Test Parameters
1.In compliance to TIA 568, the single performance parameter for field testing of fiber
optic links shall be link attenuation (insertion loss).
2.The link attenuation shall be calculated by the following formulas specified in
ANSI/TIA/EIA 568:
a.Link Attenuation = Cable Attenuation + Connector Attenuation + Splice
Attenuation.
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b.Cable Attenuation (db) = Attenuation Coefficient (db/km) x Length (km).
c.Connector Attenuation (db) = number of connector pairs x connector loss (db).
Maximum allowable connector loss = 0.75 db.
d.Splice Attenuation (dB) = number of splices (S) x Splice loss (db). Maximum
allowable splice loss = 0.3 db.
e.The values for the Attenuation Coefficient are listed below:
1)Single mode (outside plant), 1310 nm: 0.5 db/km.
2)Single mode (outside plant), 1550 nm: 0.5 db/km.
3)Multimode, 850 nm: 3.5 db/km.
4)Multimode, 1300 nm: 1.0 db/km.
f.Link attenuation shall not include any active devices or passive devices other than
cable, connectors, and splices; i.e., link attenuation shall not include such devices
as optical bypass switches, couplers, repeaters, or optical amplifiers.
g.Test equipment that measures the link length and automatically calculates the
link loss based on the above formulas is preferred.
3.The above link test limits attenuation is based on the use of the One Reference Jumper
Method specified by TIA-526-7, Method A.1; or the equivalent method. The user shall
follow the procedures established by these standards or application notes to
accurately conduct performance testing.
4.Multimode distribution links shall be tested at 850 nm and 1300 nm in accordance
with ANSI/ElA/TIA-526-14. Because backbone length and the potential number of
splices vary depending upon site conditions, the link attenuation equation shall be
used to determine limit (acceptance) values.
5.Single-mode backbone links shall be tested at 1310 nm and 1550 nm in accordance
with TIA-526-7, Method A.1, One Reference Jumper or the equivalent method. All
single-mode links shall be certified with test tools using laser light sources at 1310 nm
and 1550 nm.
6.Links to be used with network applications that use laser light sources (under-filled
launch conditions) shall be tested with test equipment based on laser light sources.
This rule shall be followed for cabling systems to support Gigabit Ethernet. Gigabit
Ethernet only specifies laser light sources. For Gigabit Ethernet compliant certification
(IEEE Std 802.3Z application), use test equipment that uses a VCSEL (Vertical cavity
surface emitting laser) at 850 nm (compliant with 1000BASESX) and a FP laser at 1310
nm (compliant with 1000BASELX).
7.Each fiber optical link terminated with an optical adapter system that does not impose
a transmission direction because the adapters are not or cannot be ganged shall be
tested and documented in both directions since the direction of the signal
transmission cannot be predicted at the time of installation.
D.OTDR Testing
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1.All cables shall be OTDR tested at 1310 nm and 1550 nm (for single mode) operating
wavelengths for anomalies and to ensure uniformity of cable attenuation and
connector insertion loss.
2.OTDR tests shall be performed utilizing a pulse suppressor such that the FDP
termination shall be shown.
3.All OTDR testing procedures and field test instruments shall comply with applicable
requirements of:
a.TIA 455-78.
b.TIA 455-133.
4.Each fiber link and channel shall be tested in one direction.
5.A launch cable shall be installed between the OTDR and the first link connection.
6.A receive cable shall be installed after the last link connection.
7.Optical Return Loss (ORL) for each link shall be measured.
8.Fiber Length shall be measured.
9.Test Results
a.Reflective events shall not exceed -40 dB.
b.Connections shall not exceed 0.75 dB of attenuation.
c.Non-reflective events (splices) shall not exceed 0.3 db.
d.Point discontinuities shall not exceed 0.1 db.
e.ORL shall be less than -30 Db.
10.OTDR Test results shall include OTDR link and channel traces and event tables at the
required wavelength(s) and the length for each optical fiber as calculated by the OTDR.
11.An Optical Spectrum scan of each link shall be performed using an optical spectrum
analyzer and optical switch to examine fiber nonlinear effects including but limited to
Brillouin scattering and four wave mixing across the fiber's usable light spectrum.
12.Polarized Modal Dispersion (PMD) for each link shall be measured using a PMD
analyzer and polarized light source. Total PMD for each link shall be less than 10 ps.
E.Cable Plant Test Result Documentation
1.The test result information for each link shall be recorded in the memory of the field
tester upon completion of the test.
2.The test result records saved by the test instrument shall be transferred into a
Microsoft Windows-based database utility that allows for the maintenance, inspection
and archiving of these test records. A guarantee shall be made that these results are
transferred to the PC unaltered, i.e., "as saved in the tester" at the end of each test.
The popular 'csv' format (comma separated, value format) does not provide adequate
protection and shall not be acceptable.
3.The raw database records of all fiber shall be stored and delivered on USB; this USB
shall include the software tools required to view, inspect, and print any selection of
test reports.
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4.A paper copy of the test results shall be provided that lists all the links that have been
tested with the following summary information.
a.The identification of the link in accordance with the naming convention defined in
the overall system documentation.
b.The overall Pass/Fail evaluation of the link-under-test including the Attenuation
worst-case margin (margin is defined as the difference between the measured
value and the test limit value).
c.The date and time the test results were saved in the memory of the tester.
5.General Information to be provided in the electronic data base containing the test
result information for each link:
a.Site identification.
b.The overall Pass/Fail evaluation of the link-under-test.
c.The name of the standard selected to execute the stored test results.
d.The cable type and the value of the 'index of refraction' used for length
calculations.
e.The date and time the test results were saved in the memory of the tester.
f.The brand name, model and serial number and calibration data of the tester.
g.The revision of the tester software and the revision of the test standards
database in the tester.
6.The detailed test results data to be provided in the electronic database for each tested
optical fiber shall contain the following information:
a.Identification of the link/fiber in accordance with the naming convention defined
in the overall system documentation.
b.The insertion loss (attenuation) measured at each wavelength, the test limit
calculated for the corresponding wavelength and the margin (difference between
the measured attenuation and the test limit value).
c.The link length shall be reported for each optical fiber for which the test limit was
calculated based on the formulas specified herein under Cable Plant Performance
Test Paragraphs.
END OF SECTION
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SECTION 31 10 00
SITE CLEARING
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section specifies site clearing activities including trees and vegetation removal and root
grubbing, tree protection, topsoil stripping and stockpiling, capping and removing utilities,
temporary erosion and sedimentation control measures, and removingminor above-and
below-grade site improvements.
This section does not include detailed tree protection and trimming, tree and root pruning,
or tree relocation; grading, excavating, backfilling for earthwork and trenching; building and
selective demolition; or landscaping.
Related Sections include the following:
Section 02 41 19,"Selective Demolition" for partial demolition of buildings or
structures undergoing alterations.
Section 0241 00"Demolition" for demolition of buildings, structures, and site
improvements.
Section 31 20 00,"Earthwork" for soil materials, excavating, backfilling, and site
grading.
1.3DEFINITIONS
Interfering or Objectionable Material: Trash, rubbish, and junk; vegetation and other organic
matter, whether alive, dead, or decaying.
Clearing: Removal of interfering or objectionable material lying on or protruding above
ground surface.
Grubbing: Removal of vegetation and other organic matter, including stumps, buried logs,
and roots greater than 2-inch caliber to a depth as specified in the following paragraphs.
Scalping: Removal of sod without removing more than upper 3-inches of topsoil.
Stripping: Removal of topsoil remaining after applicable scalpingis completed.
Topsoil: Natural or cultivated surface-soil layer containing organic matter and sand, silt, and
clay particles; friable, pervious, and black or a darker shade of brown, gray, or red than
underlying subsoil; reasonably free of subsoil, clay lumps, gravel, and other objects more
than 2-inchesin diameter; and free of subsoil and weeds, roots, toxic materials, or other
non-soil materials.
Tree Protection Zone: Area surrounding individual trees or groups of trees to be protected
during construction, and defined by the drip line of individual trees or the perimeter drip line
of groups of trees, unless otherwise indicated.
Project Limits: Areas, as shown or specified, within which work is to be performed.
1.4MATERIAL OWNERSHIP
Except for stripped topsoil or other materials indicated to remain OWNER'Sproperty, cleared
materials shall becomeCONTRACTOR’sproperty and shall be removed from Project site.
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1.5SUBMITTALS
Photographs or videotape, sufficiently detailed, of existing conditions of trees and plantings,
adjoining construction, and site improvements that might be misconstrued as damage
caused by site clearing.
Record drawings, according to Section 01 78 39,"Project Record Documents," identifying
and accurately locating capped utilities and other subsurface structural, electrical, and
mechanical conditions.
1.6PROJECT CONDITIONS
Traffic: Minimize interference with adjoining roads, streets, walks, and other adjacent
occupied or used facilities during site-clearing operations.
Do not close or obstruct streets, walks, or other adjacent occupied or used facilities
without permission from OWNERand authorities having jurisdiction.
Provide alternate routes around closed or obstructed traffic ways if required by
authorities having jurisdiction.
Salvable Improvements: As applicable, carefully remove items indicated to be salvaged and
store on OWNER'Spremises where indicated.
Utility Locator Service: Notify utility locator service for area where Project is located before
site clearing.
Do not commence site clearing operations until temporary erosion and sedimentation control
measures are in place.
PRODUCTS(NOT USED)
EXECUTION
3.1PREPARATION
Protect and maintain benchmarks and survey control points from disturbance during
construction.
Locate and clearly flag trees and vegetation to remain or to be relocated.
Protect existing siteimprovements to remain from damage during construction.Restore
damaged improvements to their original condition, as acceptable to Owner.
3.2TEMPORARY EROSION AND SEDIMENTATION CONTROL
Storm Water Pollution Prevention Plan (SWP3):
CONTRACTOR shall obtain a permit to discharge storm water from the construction
site from Texas Commission on Environmental Quality (TCEQ) in accordance with
TPDES General Permit No. TXR150000 (Permit).
The CONTRACTOR shall comply with all requirements of the Permit, including the
development of a SWP3, filling of the Notice of Intent (NOI) and Notice of
Termination (NOT), record maintenance, and posting of the Permit.
Costs associated with obtaining and compliance with the Permit arethe
CONTRACTOR’S responsibility.
Submit a copy of theSWP3 and other pertinent TCEQ submittals to the ENGINEER
and the OWNER two weeks prior to submitting to TCEQ.
Temporary Erosion and Sedimentation Control:
Provide temporary erosion and sedimentation control measures to prevent soil erosion
and discharge of soil-bearing water runoff to adjacent properties and walkways,
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according to a sediment and erosion control plan, specific to the site, which complies
with the requirements of TCEQ, or EPA832/R-92-005, or requirements of authorities
having jurisdiction, whichever is more stringent.
The CONTRACTOR shall have the sole responsibility for the means, methods,
techniques, sequences, and procedures for furnishing, installing and maintaining the
erosion and sedimentation control system.
Inspect, repair, and maintain erosion and sedimentation control measures during
construction until permanent vegetation has been established.
Remove erosion and sedimentation controls and restore and stabilize areas disturbed
during removal.
3.3TREE PROTECTION
Erect and maintain temporary fencing around tree protection zones before starting site
clearing. Remove fence when construction is complete.
Do not store construction materials, debris, or excavated material within fenced area.
Do not permit vehicles, equipment, or foot traffic within fenced area.
Maintain fenced area free of weeds and trash.
Do not excavate within tree protection zones, unless otherwise indicated.
Where excavation for new construction is required within tree protection zones, hand clear
and excavate to minimize damage to root systems. Use narrow-tine spading forks, comb
soil to expose roots, and cleanly cut roots as close to excavation as possible.
Cover exposed roots with burlap and water regularly.
Temporarily support and protect roots from damage until they are permanently
redirected and covered with soil.
Coat cut faces of roots more than 1-1/2 inchesin diameter with emulsifiedasphalt or
other approved coating formulated for use on damaged plant tissues.
Backfill with soil as soon as possible.
Repair or replace trees and vegetation indicated to remain that are damaged by construction
operations, in a manner approved by ENGINEER.
Employ an arborist, licensed in jurisdiction where Project is located, to submit details
of proposed repairs and torepair damage to trees and shrubs.
Replace trees that cannot be repaired and restored to full-growth status, as
determined by ENGINEER.
3.4UTILITIES
Locate, identify, disconnect, and cap off utilities indicated to be removed.Arrange with
utility companies to shut off indicated utilities.
Existing Utilities: If applicable, do not interrupt utilities serving facilities occupied by OWNER
or others unless permitted under the following conditions and then only after arranging to
provide temporary utility services according to requirements indicated:
Notify ENGINNER not less than two days in advance of proposed utility interruptions.
Do not proceed with utility interruptions without ENGINEER'Swritten permission.
Excavate for and remove underground utilities as indicated to be removed.
3.5LIMITS OF CLEARING
As follows, but not to extend beyond Project limits shown on the Drawings.
Excavation: 5 feet beyond top of cut slopes.
Fill:
Clearing and Grubbing: 5 feet beyond toe of permanent fill.
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Stripping: 2 feet beyond toe of permanent fill.
Roadways: Clearing and grubbing 20 feet from roadway centerline.
Overhead Utilities: Clearing and grubbing entire width of easements and rights-of-
way.
Other Areas: As shown on drawings.
Remove rubbish, trash and junk from entire area within Project limits.
3.6BLASTING
Explosives: Do not use explosives.
3.7BURNING
Unless otherwise indicated, burning will only be allowed when the CONTRACTOR provides
the OWNER with copies of written authorization from all appropriate and responsible
regulatory agencies indicating that burning is acceptable. Said regulatory agencies may
include, but not be limited to, State, City, County or local officials, fire marshals/chiefs, etc.
3.8CLEARING AND GRUBBING
Remove obstructions, trees, shrubs, grass,and other vegetation to permit installation of
new construction.
Do not remove trees, shrubs, and other vegetation indicated to remain or to be
relocated.
Cut minor roots and branches of trees indicated to remain in a clean and careful
manner where such roots and branches obstruct installation of new construction.
Grind stumps and remove roots, obstructions, and debris extending to a depth of
18-inchesbelow exposed subgrade.
Use only hand methods for grubbing within tree protection zone.
Chip removed treebranches and dispose of off-site.
As required, fill depressions caused by clearing and grubbing operations with satisfactory soil
material unless further excavation or earthwork is indicated.
Place fill material in horizontal layers not exceeding a loose depth of 8-inches, and
compact each layer to a density equal to adjacent original ground.
3.9TOPSOIL STRIPPING
Remove sod and grass before stripping topsoil.
Strip topsoil toa depth of 12inches in a manner to prevent intermingling with underlying
subsoil orother waste materials.
Remove subsoil and non-soil materials from topsoil, including trash, debris, weeds,
roots, and other waste materials.
Topsoil can be stockpiled and used for final grading whereapproved for use in
Division 2 specifications.
Remove organic material remaining after stripping topsoil. Removal depths shall be verified
in the field by the Geotechnical Engineer before filling in pockets where organic material was
removed.
Proofrolling
Following stripping of top soil, proofroll the site with a loaded tandem axle truck to
locate any soft or unstable areas. Proofrolling shall be conducted in the presence of
and approved by the Geotechnical Engineer.
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Soft or unstable areas shall be removed down to a stable subgrade as determined by
the Geotechnical Engineer, and then filled in with select fill material.
Subgrade Preparation
Following proofrolling, the following preparations shall be made to the subgrade in
the following order.
Scarify the site.
Moisture condition to above optimum moisture content.
Recompact to a minimum 95% dry density Standard Proctor (ASTM D 698).
Stockpile topsoil materialsand removed soft, unstable, and organic materialsaway from
edge of excavations without intermixing with subsoil. Grade and shape stockpiles to drain
surface water. Cover to prevent windblown dust.
Limit height of topsoil stockpiles to approximately 6feet.
Do not stockpile topsoil within tree protection zones.
Dispose of excess topsoil as specified for waste material disposal.
3.10SITE DEMOLITION
Remove existing above-gradeand below-grade improvements as indicated and as necessary
to facilitate new construction.
Remove slabs, paving, curbs, gutters, and aggregate base as indicated.
Neatly saw-cut length of existing pavement to remain attheline of demolition before
removing existing pavement. Saw-cut faces vertically.
Epoxy coatcut ends of steel reinforcement in concrete to remain to prevent corrosion.
3.11DISPOSAL
Disposal:
Remove surplus soil material, unsuitable topsoil, obstructions, demolished materials,
and waste materials including trash and debris, and legally dispose of them off
OWNER'Sproperty.
Dispose of stockpiled waste materials within 30-days.
When requested by OWNER, provide copies of the landfill receipts for waste material
disposal.
END OF SECTION
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SECTION 31 20 00
EARTHWORK
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section includes the following:
Site grading.
Preparing subgrades for roadways, structures, slabs-on-grade, and related facility
work not specified elsewhere.
Excavating and backfilling for buildings and structures.
Drainage course for slabs-on-grade.
Subsurface drainage backfill for walls and trenches.
Related Sections:
Section 31 50 00,“Maintenance of Excavation Support and Protection” for shoring,
bracing, and sheet piling of excavation.
Section 31 23 00,“Excavation, Trenching, and Backfilling for Utilities” for excavation,
trenching, and backfilling for utilities.
1.3REFERENCES
Definitions.
Backfill: Soil material or controlled low-strength material used to fill an excavation.
Borrow Soil: Satisfactory soil imported from off-site for use as fill or backfill.
Completed Course: A course or layer that is ready for next layer or next phase of
Work.
Drainage Course: Course supporting the slab-on-grade that also minimizes upward
capillary flow of pore water.
Earthwork: Includes excavation, fill and compaction, grading, and disposal of waste
and surplus material.
Excavation: Removal of material encountered above subgrade elevations and to lines
and dimensions indicated.
Authorized Additional Excavation: Excavation below subgrade elevations or
beyond indicated lines and dimensions as directed by ENGINEER. Authorized
additional excavation and replacement material will be paid for according to
Contract provisions for unit prices.
Bulk Excavation: Excavation more than 10 feet in width and more than 30 feet
in length.
Unauthorized Excavation: Excavation below subgrade elevations or beyond
indicated lines and dimensions without direction by ENGINEER. Unauthorized
excavation, as well as remedial work directed by ENGINEER, shall be without
additional compensation.
Prepared Ground Surface: Ground surface after completion of required demolition,
clearing and grubbing, stripping of topsoil, excavation or fill to grade, and subgrade
preparation.
Fill: Soil materials usedto raise existing grades.
Lift: Loose (uncompacted) layer of material.
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Optimum Moisture Content: Determined in accordance with ASTM Standard specified
to determine maximum dry density for relative compaction. Determine field moisture
content on basis of fraction passing 3/4-inch sieve.
Relative Compaction: Ratio, in percent, of as-compacted field dry density to
laboratory maximum dry density as determined in accordance with ASTM D698. Apply
corrections for oversize material to either as-compacted field drydensity or maximum
dry density, as determined by ENGINEER.
Rock: Rock material in beds, ledges, unstratified masses, conglomerate deposits, and
boulders of rock material that exceed 1 cu. yd. for bulk excavation or 3/4 cu. yd. for
footing, trench, and pit excavation that cannot be removed by rock excavating
equipment equivalent to the following in size and performance ratings, without
systematic drilling, ram hammering, ripping, or blasting, when permitted:
Excavation of Footings, Trenches, and Pits: Late-model, track-mounted
hydraulic excavator; equipped with a 42-inch-wide, maximum, short-tip-radius
rock bucket; rated at not less than 138-hp flywheel power with bucket-curling
force of not less than 28,090 lbf and stick-crowd force of not less than 18,650
lbf; measured according to SAEJ-1179.
Bulk Excavation: Late-model, track-mounted loader; rated at not less than
210-hp flywheel power and developing a minimum of 48,510-lbf breakout force
with a general-purpose bare bucket; measured according to SAEJ-732.
Structures: Buildings, footings, foundations, retaining walls, slabs, tanks, curbs,
mechanical and electrical appurtenances, or other man-made stationary features
constructed above or below the ground surface.
Subgrade: Surface or elevation remaining after completing excavation, or top surface
of a fill or backfill immediately below subbase, drainage fill, or topsoil materials.
Utilities: On-site underground pipes, conduits, ducts, and cables, as well as
underground services within buildings.
Well-Graded: A mixture of particle sizes that has no specific concentrations or lack
thereof of one or more sizes producing a material type which, when compacted,
produces a strong and relatively incompressible soil mass free from detrimental voids.
Reference Standards.
ASTM International:
D448 –Standard Method Classification forsizes of Aggregate for Road and
Bridge construction.
D698 –Standard Test Methods for Laboratory Compaction Characteristics of
Soil Using Standard Effort (12,499 ft-lb.ft3 (600 kN-m/m3))
D2487 –Standard Method Classification of Soils for Engineering Purposes
(Unified Soil Classification system)
D6938 –Standard Test Methods for In-Place Density and Water Content of Soil
and Soil-Aggregate by Nuclear Methods (Shallow Depth)
American Association of State Highways and Transportation Officials (AASHTO):
M288 –Geotextile Specification for Highway Application
Texas Department of Transportation: Standard Specifications for Construction of
Highways, Streets and Bridges. (TxDOT).
TxDOT Item 216 “Proof Rolling”
1.4SUBMITTALS
Product Data: For the following:
Geotextile, if specified on Drawings.
Controlled low-strength material, including design mixture.
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Samples: 12-by-12-inch Sample of subdrainage and/or separation geotextile.
Material Test Reports: From a qualified testing agency indicating and interpreting test
results for compliance of the following with requirements indicated:
Classification according to ASTMD2487 of each on-site and borrow soil material
proposed for fill and backfill.
Laboratory compaction curve according to ASTMD698 for each on-site and borrow
soil material proposed for fill and backfill.
Designated submittals for materials per Section31 05 16,“Aggregates for Earthwork.”
Pre-excavation Photographs or Videotape: Show existing conditions of adjoining
construction and site improvements, including finish surfaces, which might be misconstrued
as damage caused by earthwork operations. Submit before earthwork begins.
1.5PROJECT CONDITIONS
Existing Utilities: If applicable, do not interrupt utilities serving facilities occupied by OWNER
or others unless permitted in writing by ENGINEER and then only after arranging to provide
temporary utility services according to requirements indicated.
Notify ENGINEER not less than two days in advance of proposed utility interruptions.
Do not proceed with utility interruptions without ENGINEER'S written permission.
Contact utility-locator service for area where Project is located before excavating.
Demolish and completely remove fromsite existing underground utilities as indicated to be
removed. Coordinate with utility companies to shut off services if lines are active.
Weather Limitations:
0
Material excavated when frozen or when air temperature is less than 32F shall not
be used as fill or backfill until material completely thaws.
Material excavated during inclement weather shall not be used as fill or backfill until
after material drains and dries sufficiently for proper compaction.
PRODUCTS
2.1SOIL MATERIALS
General: Provide borrow soil materials when sufficient satisfactory soil materials are not
available from excavations.
Satisfactory Soils: ASTMD2487 Soil Classification GroupsGW, GP, GM, SW, SP, and SMor
a combination of these groups; free of rock or gravel larger than 3inches in any dimension,
debris, waste, frozen materials, vegetation, and other deleterious matter. Satisfactory soils
shall comply with the requirements of Section 31 05 16,“Aggregates for Earthwork.”
Unsatisfactory Soils: Soil Classification GroupsGC, SC, CL, ML, OL, CH, MH, OH, and PT
according to ASTMD2487 or a combination of these groups.
Unsatisfactory soils also include satisfactory soils not maintained within 2 percent of
optimum moisture content at time of compaction.
Depending on the plasticity index (PI) and liquid limits (LL),Soil Classification Groups
GC and SC may be used.
Excavated backfill may be used for general site fill but may not be used for select fill.
2.2DRAINAGE COURSE AND FILTER MATERIAL
Drainage Course: Narrowly graded mixture of washedcrushed stone, or crushed or
uncrushed gravel; ASTMD448; coarse-aggregate grading Size57; with 100 percent passing
a 1-1/2-inch sieve and 0 to 5 percent passing a No.8 sieve.
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Filter Material: Narrowly graded mixture of natural or crushed gravel, or crushed stone and
natural sand; ASTMD448; coarse-aggregate grading Size67; with 100 percent passing a 1-
inch sieve and 0 to 5 percent passing a No.4 sieve.
2.3GEOTEXTILES
Subsurface Drainage Geotextile: When shown on Drawings, provide non-woven needle-
punched geotextile, manufactured for subsurface drainage applications, made from
polyolefin or polyesters; with elongation greater than 50 percent; complying with
AASHTOM288 and the following, measured per test methods referenced:
Survivability: Class2; AASHTOM288.
Grab Tensile Strength: 157 lbf; ASTMD4632.
Sewn Seam Strength: 142 lbf; ASTMD4632.
Tear Strength: 56 lbf; ASTMD4533.
Puncture Strength: 56 lbf; ASTMD4833.
Apparent Opening Size: No.60 sieve, maximum; ASTMD4751.
Permittivity: 0.2 per second, minimum; ASTMD4491.
UV Stability: 50 percent after 500 hours' exposure; ASTMD4355.
Separation Geotextile: If shown on the Drawings, provide woven geotextile fabric,
manufactured for separation applications, made from polyolefin or polyesters; with
elongation less than 50 percent; complying with AASHTOM288 and the following,
measured per test methods referenced:
Survivability: Class2; AASHTOM288.
Grab Tensile Strength: 247 lbf; ASTMD4632.
Sewn Seam Strength: 222 lbf; ASTMD4632.
Tear Strength: 90 lbf; ASTMD4533.
Puncture Strength: 90 lbf; ASTMD4833.
Apparent Opening Size: No.60 sieve, maximum; ASTMD4751.
Permittivity: 0.02 per second, minimum; ASTMD4491.
UV Stability: 50 percent after 500 hours' exposure; ASTMD4355.
2.4MATERIAL QUALITY CONTROL
Sampling of material stockpiles and material sources shall be in accordance with ASTM D75.
Perform gradation analysis in accordance with ASTM C136 for:
Coarse and fine aggregate, natural gravel, crushed stone for foundation, sand, select
fill, impervious clay fill, earth fill, and topsoil.
Perform abrasion testing in accordance with ASTM C131 or ASTM C535.
Coarse and fine aggregate and when requested by ENGINEER for natural gravel and
crushed stone for foundation.
Soundness testing in accordance with ASTM C88.
Coarse and fine aggregate and when requested by ENGINEER for natural gravel and
crushed stone for foundation.
Deleterious materials determination in accordance with ASTM C40, C117, and C142.
Coarseand fine aggregate and when requested by ENGINEER for natural gravel and
crushed stone for foundation
Determine liquid limit and plasticity index in accordance with ASTM D4318.
Sand for particles passing No. 8 sieve, select fill, impervious clay fill, andearth fill.
Determine pH of topsoil in accordance with ASTM D2974.
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Determine permeability (hydraulic gradient) in accordance with ASTM D5084 and percent
dispersion in accordance with ASTM D4221 of impervious clay fill materials.
Provide tests results showing flowable fill mix design achieves desired compressive strength.
2.5CONTAMINATION TESTING AND CERTIFICATION
When materials are suspected of contamination, the CONTRACTOR shall arrange and pay
for the services of an EPA approved laboratory to perform a toxic contaminant scan of
composite borrow material samples in accordance with Section 31 05 16,“Aggregates for
Earthwork.”
Soil materials derived from the excavation of underground petroleum storage tanks shall not
be used as fill on Project.
EXECUTION
3.1PREPARATION
Protect structures, utilities, sidewalks, pavements, and other facilities from damage caused
by settlement, lateral movement, undermining, washout, and other hazards created by
earthwork operations.
Preparation of subgrade for earthwork operations including removal of vegetation, topsoil,
debris, obstructions, and deleterious materials from ground surface is specified in
Section31 10 00,"Site Clearing."
Protect and maintain erosion and sedimentation controls, which are specified in
Section31 10 00,"Site Clearing," during earthwork operations.
Provide excavation support and protection in accordance with Section 31 50 00,
“Maintenance of Excavation Support and Protection”.
Excavation, trenching, and backfilling work for utilities shall be accomplished in accordance
with Section 31 23 00,“Excavation, Trenching, and Backfilling for Utilities.”
3.2DEWATERING
Prevent surface water and ground water from entering excavations, from ponding on
prepared subgrades, and from flooding Project site and surrounding area.
Protect subgrades from softening, undermining, washout, and damage by rain or water
accumulation.
Reroute surface water runoff away from excavated areas. Do not allow waterto
accumulate in excavations. Do not use excavated trenches as temporary drainage
ditches.
Install a dewatering system,specified in Section 31 23 19,"Dewatering," to keep
subgrades dry and convey ground water away from excavations. Maintain until
dewatering is no longer required.
3.3EXPLOSIVES
No explosives of any kind will be allowed on site at any time.
3.4EXCAVATION, GENERAL
Excavations shall be observed by the Geotechnical Engineer to make sure that the proper
bearing material has been reached. The excavations shall be checked for size and observed
by the Geotechnical Engineer to make sure that loose material has been removed prior to
concrete placement.
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Unclassified Excavation: Excavate to subgrade elevations regardless of the character of
surface and subsurface conditions encountered. Unclassified excavated materials may
include rock, soil materials, and obstructions. No changes in the Contract Sum or the
Contract Time will be authorized for rock excavation or removal of obstructions.
If excavated materials intended for fill and backfill include unsatisfactory soil materials
and rock, replace with satisfactory soil materialsfrom an approved quarry. Submit
quarry test results to ENGINEER for approval prior to use.
Remove rock to lines and grades indicated to permit installation of permanent
construction without exceeding the following dimensions:
24 inches outside of concrete forms other than at footings.
12 inches outside of concrete forms at footings.
6 inches outside of minimum required dimensions of concrete cast against
grade.
Outside dimensions of concrete walls indicated to be cast against rock without
forms or exterior waterproofing treatments.
6 inches beneath bottom of concrete slabs on grade.
3.5EXCAVATION FOR STRUCTURES
Excavate to specifiedelevations and dimensions within a tolerance of plus or minus 1 inch.
If applicable, extend excavations a sufficient distance from structures for placing and
removing concrete formwork, for installing services and other construction, and for
inspections. Submit quarry test results to ENGINEER for approval prior to use.
Excavations for Footings and Foundations: Do not disturb bottom of excavation.
Excavate by hand to final grade just before placing concrete reinforcement. Trim
bottoms to required lines and grades to leave solid base to receive other work. Refer
to Drawings for treatment of subgrade, the addition of a concrete seal slab,
installation of vapor barrier, or other work required prior to placement of footings and
foundations.
Pile Foundations: Stop excavations 6 to 12 inches above bottom of pile cap before
piles are placed. After piles have been driven, remove loose and displaced material.
Excavate to final grade, leaving solid base to receive concrete pile caps.
Excavation for Underground Tanks, Basins, and Mechanical or Electrical Utility
Structures: Excavate to elevations and dimensions indicated within a tolerance of
plus or minus 1 inch. Do not disturb bottom of excavations intended as bearing
surfaces.
Undercutting:
When objectionablematerial not suitable for foundation or subgrade material is
present in locations for subgrade or foundation construction, as determined by
ENGINEER, undercut material to the depth and extent as directed and backfill with
suitable material.
Place fill material in uniform layers and compact as specifiedfor soil backfill and fills.
Dispose of undercut materials off-site.
3.6SUBGRADE INSPECTION
Notify ENGINEER when excavations have reached required subgrade.
If ENGINEER determines that unsatisfactory soil is present, continue excavation and replace
with compacted backfill or fill material as directed.
Proofroll subgrade to identify soft pockets and areas of excess yielding using rollers that
when loaded weigh at least 25 tons and no morethan 50 tons.
Do not proof-roll wet or saturated subgrades.
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Make at least two passes, offsetting each pass one tire width. Operate at speed
between 2 and 6 miles per hour.
Excavate softpockets, unsatisfactory soils, and areas of excessive pumping or rutting,
as determined by ENGINEER, and replace with selectfill as directed.
Following proofrolling and replacement of unsatisfactory soil with satisfactory soil, the
following preparations shall be made to the subgrade in the following order.
Scarify the site
Moisture condition to above optimum moisture content
Recompact to a minimum 95% dry density Standard Proctor (ASTM D 698)
Work in areas under TxDOT jurisdiction, proofroll in accordance with TxDOT Item
216.
Authorized additional excavation and replacement material will be paid for according to
Contract provisions for unit prices.
Reconstruct subgrades damaged by freezing temperatures, frost, rain, accumulated water,
or construction activities, as directed by ENGINEER, without additional compensation.
3.7UNAUTHORIZED EXCAVATION
Fill unauthorized excavation under foundations or wall footings by extending bottom
elevation of concrete foundation or footing to excavation bottom, without altering top
elevation. Lean concrete fill, with 28-day compressive strength of 2500 psi, may be used
when approved by ENGINEER.Fill unauthorized excavations under other construction or
utility pipe as directed by ENGINEER.
3.8STORAGE OF SOIL MATERIALS
Stockpile borrows soil materials and excavated satisfactory soil materials without
intermixing. Place, grade, and shape stockpiles to drain surface water. Cover to prevent
windblown dust.
Stockpile soil materials away from edge of excavations. Do not store within drip line
of remaining trees.
Confine stockpiles to within easements, right-of-way, and approved areas. Do not
obstruct roads or streets.
3.9BACKFILL
Place and compact backfill in excavations promptly, but not before completing the following
work as applicable:
Construction below finish grade including, where applicable, subdrainage, damp
proofing, waterproofing, and perimeter insulation.
Surveying locations of underground utilities for Record Documents.
Testing and inspecting underground utilities.
Removing concrete formwork.
Removing trash and debris.
Removing temporary shoring and bracing, and sheeting.
Installing permanent or temporary horizontal bracing on horizontally supported walls.
Leakage tests for structures.
Place backfill on subgrades free of mud, frost, snow, or ice.
3.10SOIL FILL
Plow, scarify, bench, or break up sloped surfaces steeper than 1 vertical to 4 horizontal so
fill material will bond with existing material.
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Place and compact fill material in layers to required elevations as follows:
Under grass and planted areas, use satisfactory soil material.
Under walks and pavements, use satisfactory soil material.
Under steps and ramps, use select or granular fill, unless otherwise shown on
Drawings.
Under building slabs, use select fill, unless otherwise shown on drawings.
Place soil fills on subgrades free of mud, frost, snow, or ice.
3.11SOIL MOISTURE CONTROL
Uniformly moisten or aerate subgrade and each subsequent fill or backfill soil layer before
compaction to within 2 percent of optimum moisture content, if not specified on the
Drawings or in the Geotechnical Report.
Do not place backfill or fill soil material on surfaces that are muddy, frozen, or contain
frost or ice.
Remove and replace, or scarify and air dry otherwise satisfactory soil material that
exceeds optimum moisture content by 2 percent and istoo wet to compact to
specified dry unit weight.
Do not allow the moisture content in the subgrade and layers below the slab base to
fall below the optimum moisture content.
Vapor Barrier: Place polyethylenesheeting below the concrete slabs. If the subgrade
underlying the vapor barrier contains sharp or angled particles, then a layer of cushion sand
(1 to 2-inches thick) should be placed in contact with the sheet to provide protection against
puncture. Note that the elevation and thickness of the slab shall not be changed to adjust
for the layer of cushion sand.
3.12COMPACTION OF SOIL BACKFILLS AND FILLS
Place backfill and fill soil materials in layers not more than 6inchesin loose depth for
material compacted by heavy compaction equipment, and not more than 4 inches in loose
depth for material compacted by hand-operated tampers.
Place backfill and fill soil materials evenly on all sides of structures to required elevations,
and uniformly along the full length of each structure.
Compact soil materials to not less than the following percentages of maximum dry unit
weight according to ASTMD698, if not specified on the Drawings:
For raft/mat foundation areas, scarify and compact top 12 inches of existing subgrade
and each layer of backfill or fill soil material to 98percent.
For other areas at the site, scarify and compact top 6 inches below subgrade and
compact each layer of backfill or fill soil material at 98 percent.
Avoid over compaction of the subgrade and any other layers of backfill or fill soil.
3.13GRADING
General: Uniformly grade areas to a smooth surface, free of irregular surface changes.
Comply with compaction requirements and grade to cross sections, lines, and elevations
indicated.
Provide a smooth transition between adjacent existing grades and new grades.
Cut out soft spots, fill low spots, and trim high spots to comply with required surface
tolerances.
Site Grading: Slope grades to direct water away from buildings and structuresand to
prevent ponding. Finish subgrades to required elevations within the following tolerances:
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Lawn or Unpaved Areas: Plus or minus 1-inch.
Walks: Plus or minus 1inch.
Pavements: Plus or minus 1/2 inch.
Grading inside Building Lines: Finish subgrade to a tolerance of 1/2 inch when tested with a
10-foot straightedge.
3.14SUBSURFACE DRAINAGE
When shown on the Drawings, provide subsurface drainage in accordance with the following
paragraphs.
Subdrainage Pipe: Specified in Section 33 41 00,"Subdrainage."
Subsurface Drain: Place subsurface drainage geotextile around perimeter of subdrainage
trench. Place a 6inch course of filter material on subsurface drainage geotextile to support
subdrainage pipe. Encase subdrainage pipe in a minimum of 12inches of filter material,
placed in compacted layers 6inches thick, and wrap in subsurface drainage geotextile,
overlapping sides and ends at least 6inches.Compact each filter material layer with a
minimum of two passes of a plate-type vibratory compactor.
Drainage Backfill: Place and compact filter material over subsurface drain, in width
indicated, to within 12inches of final subgrade, in compacted layers 6inches thick. Overlay
drainage backfill with onelayer of subsurface drainage geotextile, overlapping sides and
ends at least 6inches.
Compact each filter material layer with a minimum of two passes of a plate-type
vibratory compactor.
As shown on the Drawings, place and compact impervious fill over drainage backfill in
6inch thick compacted layers to final subgrade.
3.15DRAINAGE COURSE
Place drainage course onsubgrades free of mud, frost, snow, or ice.
On prepared subgrade, place and compact drainage course under cast-in-place concrete
slabs-on-grade as follows:
Install subdrainage geotextile on prepared subgrade according to manufacturer's
written instructions, overlapping sides and ends.
Place drainage course 6-inches or less in compacted thickness in a single layer.
Place drainage course that exceeds 6-inches in compacted thickness in layers of equal
thickness, with no compacted layer more than 6-inches thick or less than 3inches
thick.
Compact each layer of drainage course to required cross sections and thicknesses to
not less than 95 percent of maximum dry unit weight according to ASTMD698.
3.16CONCRETE SEAL SLAB
When shown on the Drawings, provide a concrete seal slab on subgrade under structures of
the specified thickness. Concrete shall comply with Section 03 30 00,“Cast-In-Place
Concrete”having a compressive strength of 3,000 psi.
3.17CEMENT-SOIL BACKFILL
When shown on the Drawings, provide cement-soil backfill as subgrade under structures.
Cement-Soil Backfill shall comply with Section 31 05 16,“Aggregates for Earthwork.”
Mix not less than 1-1/2 sacks of Portland cement per cubic yard of sand with water using a
pug mill type mixer. Stamp batch ticket with time of loading. Material will be rejected if not
place within 1-1/2 hours after loading or if the mixture has dried out.
Application:
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Pipes and Conduits. Use cement-sand material as bedding and backfill for pipes,
conduits and other utilities as indicated on the Drawings or because of site conditions.
Foundations. Use cement-sand material for stabilizing foundation for manholes, inlets
or other utility or drainage structures.
Manholes. Use cement-sand material as backfill around manholes if the manhole
adjoins pavement.
Density Control:
Place in lifts not exceeding 12-inches measured loose. Compact with
mechanical hand tamps in accordance with Density Control requirements.
Areas Subjected to or Influenced by Vehicular Traffic. Unless otherwise
indicated on the Drawings, compact backfill to a minimum 100 percent of
maximum density as determined in accordance with ASTM D698, with required
moisture content within minus 2 to plus 4 of optimum.
Areas Not Subjected to or Influenced by Vehicular Traffic. Unless otherwise
indicated on the Drawings, compact backfill to a minimum 95 percent of
maximum density as determined in accordance with ASTM D698, with required
moisture content within minus 2 to plus 4 of optimum.
Field Quality Control
Test Method:
Determine the maximum density and the optimum moisture content of
pipe zone and backfill materials in accordance with ASTM D698.
Determination of density control backfill materials shall be in accordance
with ASTM D2922.
Compaction Test Frequency:
For trench lengths less than 300 feet, around structures and manholes,
minimum of one test for each layer of backfill.
For trench lengths in excess of 300 feet, perform a minimum of one test
for every 300 linear feet for each layer of backfill.
3.18FIELD QUALITY CONTROL
Allow testing agency to inspect and test subgrades and each fill or backfill layer. Proceed
with subsequent earthwork only after test results forpreviously completed work comply with
requirements.
Footing Subgrade: At footing subgrades, at least one test of each soil stratum will be
performed to verify design bearing capacities. Subsequent verification and approval of other
footing subgrades maybe based on a visual comparison of subgrade with tested subgrade
when approved by ENGINEER.
Testing agency will test compactionin accordance with ASTMD2922 and moisture content
in accordance with ASTMof soils. Tests for both compaction and moisture content will be
performed at the following locations and frequencies:
Paved and Building Slab Areas: At subgrade and at each compacted fill and backfill
layer, at least 1 test for every 2500 sq. ft., but in no case fewer than 2testsat each
layer.
Foundation Wall Backfill: At each compacted backfill layer, at least 1 test for each
100 feet or less of wall length, but no fewer than 2 tests.
Pavement Areas: At subgrade and at each compacted fill and backfill layer, least 1
test for every 5,000 sq. ft,
Trenches: At each compacted fill and backfill layer, at least 1 test per 100 linear feet
of trench.
When testing agency reports that subgrades, fills, or backfills have not achieved degree of
compaction specified, scarify and moisten or aerate, or remove and replace soil to depth
required; recompact and retest until specified compaction is obtained.
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3.19PROTECTION
Protecting Graded Areas: Protect newly graded areas from traffic, freezing, and erosion.
Keep free of trash and debris.
Repair and reestablish grades to specifytolerances where completed or partially completed
surfaces become eroded, rutted, settled, or where they lose compaction due to subsequent
construction operations or weather conditions.
Scarify or remove and replacesoil material to depth as directed by ENGINEER;
reshape and recompact.
Where settling occurs before Project correction period elapses, remove finished surfacing,
backfill with additional soil material, compact, and reconstruct surfacing.
Restore appearance, quality, and condition of finished surfacing to match adjacent
work, and eliminate evidence of restoration to greatest extent possible.
3.20DISPOSAL OF SURPLUS AND WASTE MATERIALS
Disposal: Remove surplus satisfactory soil and waste material, including unsatisfactory soil,
trash, and debris, and legally dispose of it off OWNER'Sproperty.
END OF SECTION
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SECTION 31 23 16
EXCAVATION SUPPORT AND PROTECTION
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section includes temporary excavation support and protection systems.
Related Sections:
Section 31 23 19"Dewatering" for dewatering system for excavations.
1.3PERFORMANCE REQUIREMENTS
Design,furnish, install, monitor, and maintain excavation support and protection system
capable of supporting excavation sidewalls and of resisting soil and hydrostatic pressure and
superimposed and construction loads.
Delegated Design: Design excavation support and protection system, including
comprehensive engineering analysis by a qualified professional engineer, licensed to
practice in the state where the Project will be constructed, using performance
requirements and design criteria indicated.
As a minimum, the Excavation Support and Protection Plan shall address the following
items:
Provide details of shoring, bracing, sheet piling, soldier piles and lagging, tie backs,
and other support systems and provisions for worker protection from hazards of
caving ground.
Methods and sequencing of installing excavation support.
Proposed locations for excavated materials.
Minimum lateral distance from the crest of slopes for vehicles, equipment, and
stockpiled materials.
Prevent surface water from entering excavations by grading, dikes, or other means.
Install excavation support and protection systems without damaging existing
buildings, structures, and site improvements adjacent to excavation.
Monitor vibrations, settlements, and movements.
1.4SUBMITTALS
Delegated-Design Submittal: For excavation support and protection system indicated to
comply with performance requirements and design criteria, includeanalysis data signed and
sealed by the qualified professional engineer, licensed to practice in the state where the
Project is constructed, responsible for their preparation.
1.5PROJECT CONDITIONS
Project-Site Information: A geotechnical report has been prepared for this Project and is
available for information only. The opinions expressed in this report are those of the
geotechnical engineer and representinterpretations of subsoil conditions, tests, and results
of analyses conducted by geotechnical engineer. OWNER and ENGINEER will not be
responsible for interpretations or conclusions drawn from the data.
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Make additional test borings and conduct other exploratory operations necessary for
excavation support and protection.
Survey Work: Engage a qualified land surveyor or professional engineer to survey adjacent
existing buildings, structures, and site improvements; establish exact elevations at fixed
points to act as benchmarks. Clearly identify benchmarks and record existing elevations.
During installation of excavation support and protection systems, regularly resurvey
benchmarks, maintaining an accurate log of surveyed elevations and positions for
comparison with original elevations and positions. Promptly notify ENGINEERif
changes in elevations or positions occur or if cracks, sags, or other damage is evident
in adjacent construction.
PRODUCTS (NOT USED)
EXECUTION
3.1PREPARATION
Protect structures, utilities, sidewalks, pavements, and other facilities from damage caused
by settlement, lateral movement, undermining, washout, and other hazards that could
develop during excavation support and protection system operations.
Shore, support, and protect utilities encountered.
Install excavation support and protection systems to ensure minimum interference with
roads, streets, walks, and other adjacent occupied and used facilities.
Do not close or obstruct streets, walks, or other adjacent occupied or used facilities
without permission from OWNER and authorities having jurisdiction. Provide alternate
routes around closed or obstructed traffic ways if required by authorities having
jurisdiction.
Locate excavation support and protection systems clear of permanent construction so that
forming and finishing of concrete surfaces are not impeded.
Monitor excavation support and protection systems daily during excavation progress and for
as long as excavation remains open. Promptly correct bulges, breakage, or other evidence
of movement to ensure that excavation support and protection systems remain stable.
Promptly repair damages to adjacent facilities caused by installing excavation support and
protection systems.
3.2TRENCHES
For excavations exceeding 5 feet in depth, provide adequate safety system meeting
requirements of applicable state and local construction safety orders, and Federal
requirements.
3.3REMOVAL AND REPAIRS
Remove excavation support and protection systems when construction has progressed
sufficiently to support excavation and bear soil and hydrostatic pressures. Remove in stages
to avoid disturbing underlying soils or damaging structures, pavements, facilities, and
utilities.
Fill voids immediately with approved backfill compacted to density specified in Section
31 20 00"Earthwork."
Repair or replace, as approved by ENGINEER, adjacent work damaged or displaced by
removing excavation support and protection systems.
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If the support or stability of existing structures or site improvements is dependent, leave
excavation support and protection systems permanently in place. Remove excavation
support and protection systems to a minimum depth of 48 inches below overlaying
construction and abandon remainder.
END OF SECTION
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SECTION 31 23 19
DEWATERING
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section includes construction dewatering.
Related Sections:
Section 31 50 00"Maintenance of Excavation Support and Protection" for shoring,
bracing, and sheet piling of excavations.
Section 31 20 00"Earthwork" for excavating, backfilling, site grading, and for site
utilities.
Section 31 23 00“Excavation, Trenching, and Backfilling for Utilities” for excavation,
trenching and backfilling for utilities.
1.3PERFORMANCE REQUIREMENTS
Dewatering Performance: Design, furnish, install, test, operate, monitor, and maintain
dewatering system of sufficient scope, size, and capacity to control hydrostatic pressures
and to lower, control, remove, and dispose of ground water and permit excavation and
construction to proceed on dry, stable subgrades.
Delegated Design: Design dewatering system, including comprehensive engineering
analysis by a qualified professional engineerin the state where the Project is to be
constructed, using performance requirements and design criteria indicated.
Continuously monitor and maintain dewatering operations to ensure erosion control,
stability of excavations and constructed slopes, that excavation does not flood, and
that damage to subgrades and permanent structures is prevented.
Prevent surface water from entering excavations by grading, dikes, or other means.
Accomplish dewatering without damaging existing buildings, structures, and site
improvements adjacent to excavation.
Remove dewatering system when no longer required for construction.
1.4SUBMITTALS
Action Submittal. Provide shop drawings for dewatering system. Show arrangement,
locations, and details of wells and well points; locations of risers, headers, filters, pumps,
power units, and discharge lines; and means of discharge, control of sediment, and disposal
of water.
Delegated-Design Submittal: For dewatering system indicated to comply with performance
requirements and design criteria, including analysis data signed and sealed by the qualified
professional engineer responsible for their preparation.
Informational submittals
Qualification Data: For qualified Installer,land surveyor and professional engineeras
applicable.
Field quality-control reports.
Other Informational Submittals:
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Photographs or Videotape: Show existing conditions of adjoining construction
and site improvements that might be misconstrued as damage caused by
dewatering operations, if applicable.
1.5QUALITY ASSURANCE
Installer Qualifications: An experienced installer that has specialized in design of dewatering
systems anddewatering work.
Regulatory Requirements: Comply with governing notification regulations before beginning
dewatering. Comply with hauling and disposal regulations of authorities having jurisdiction.
1.6PROJECT CONDITIONS
Interruption of Existing Utilities: As applicable, do not interrupt any utility serving facilities
occupied by Owner or others unless permitted under the following conditions and then only
after arranging to provide temporary utility according to requirements indicated:
Notify Engineer no fewer than two (2) days in advance of proposed interruption of
utility.
Do not proceed with interruption of utility without ENGINEER’s written permission.
Project-Site Information: A geotechnical report has been prepared for this Project and is
available for information only. The opinions expressed in this report are those of
geotechnical engineer and represent interpretations of subsoil conditions, tests, and results
of analyses conducted by geotechnical engineer. OWNER/ENGINEERwill not be responsible
for interpretations or conclusions drawn from this data.
Make additional test borings and conduct other exploratory operations necessary for
dewatering.
The geotechnical report is referenced elsewhere in the Project Manual.
Survey Work: If applicable, engage a qualified land surveyor or professional engineer to
survey adjacent existing buildings, structures, and site improvements, establishing exact
elevations at fixed points to act as benchmarks. Clearly identify benchmarks and record
existing elevations.
During dewatering, regularly resurvey benchmarks, maintaining an accurate log of
surveyed elevations for comparison with original elevations. Promptly notify
ENGINEERif changes in elevations occur or if cracks, sags, or other damage is
evident in adjacent construction.
PRODUCTS (NOT USED)
EXECUTION
3.1PREPARATION
Protect structures, utilities, sidewalks, pavements, and other facilities from damage caused
by settlement, lateral movement, undermining, washout, and other hazards created by
dewatering operations.
Prevent surface water and subsurface or ground water from entering excavations,
from ponding on prepared subgrades, and from flooding site and surrounding area.
Protect subgrades and foundation soils from softening and damage by rain or water
accumulation.
Install dewatering systemto ensure minimum interference with roads, streets, walks, and
other adjacent occupied and used facilities.
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Do not close or obstruct streets, walks, or other adjacent occupied or used facilities
without permission from Owner and authorities having jurisdiction. Provide alternate
routes around closed or obstructed traffic ways if required by authorities having
jurisdiction.
Provide temporary grading to facilitate dewatering and control of surface water.
Monitor dewatering systems continuously.
Promptly repair damages to adjacent facilities caused by dewatering.
Protect and maintain temporary erosion and sedimentation controls, which are specified in
Section 31 10 00"Site Clearing" during dewatering operations.
3.2INSTALLATION
Install dewatering system utilizing wells, well points, or similar methods complete with pump
equipment, standby power and pumps, filter material gradation, valves, appurtenances,
water disposal, and surface-water controls.
Space well points or wells at intervals required to provide sufficient dewatering.
Use filters or other means to prevent pumping of fine sands or silts from the
subsurface.
Before excavating below ground-water level, place system into operation to lower water to
specified levels. Operate system continuously until drains, sewers, and structures have been
constructed and fill materials have been placed or until dewatering is no longer required.
Provide an adequate system to lower and control ground water to permit excavation,
construction of structures, and placement of fill materials on dry subgrades. Install
sufficient dewatering equipment to drain water-bearing strata above and below bottom of
foundations, drains, sewers, and other excavations.
Do not permit open-sump pumping that leads to loss of fines, soil piping, subgrade
softening, and slope instability.
Reduce hydrostatic head in water-bearing strata below subgrade elevations of foundations,
drains, sewers, and other excavations.
Unless otherwise specified in the Geotechnical Report, maintain piezometric water
level a minimum of 24 inches below surface of excavation.
Dispose of water removed by dewatering in a manner that avoids endangering public health,
property, and portions of work under construction or completed. Dispose of water and
sediment in a manner thatavoids inconvenience to others. Provide sumps, sedimentation
tanks, and other flow-control devices as required by authorities having jurisdiction.
Provide standby equipment on site, installed and available for immediate operation, to
maintain dewatering on continuous basis if any part of system becomes inadequate or fails.
If dewatering requirements are not satisfied due to inadequacy or failure of dewatering
system, restore damaged structures and foundation soils at no additional expense to Owner.
Remove dewatering system from Project site on completion of dewatering. Plug or fill
well holes with sand or cut off and cap wells a minimum of 36 inches below overlying
construction.
Damages: Promptly repair damages to adjacent facilities caused by dewatering operations.
3.3FIELD QUALITY CONTROL
Observation Wells: When shown on Drawings, provide, take measurements, and maintain
at least the minimum number of observation wells or piezometers indicated; additional
observation wells may be required by authorities having jurisdiction.
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Observe and record daily elevation of ground water and piezometric water levels in
observation wells.
Repair or replace, within 24 hours, observation wells that become inactive, damaged,
or destroyed. In areas where observation wells are not functioning properly, suspend
construction activities until reliable observations can be made. Add or remove water
from observation-well risers to demonstrate that observation wells are functioning
properly.
Fill observation wells, remove piezometers, and fill holes when dewatering is
completed.
Provide continual observation to ensure that subsurface soils are not being removed by the
dewatering operation.
END OF SECTION
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SECTION 31 50 00
MAINTENANCE OF EXCAVATION SUPPORT AND PROTECTION
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section includes temporary excavation support and protection systems.
Related Sections:
Section 31 23 19"Dewatering" for dewatering system for excavations.
1.3PERFORMANCE REQUIREMENTS
Design,furnish, install, monitor, and maintain excavation support and protection system
capable of supporting excavation sidewalls and of resisting soil and hydrostatic pressure and
superimposed and construction loads.
Delegated Design: Design excavation support and protection system, including
comprehensive engineering analysis by a qualified professional engineer, licensed to
practice in the state where the Project will be constructed, using performance
requirements and design criteria indicated.
As a minimum, the Excavation Support and Protection Plan shall address the following
items:
Provide details of shoring, bracing, sheet piling, soldier piles and lagging, tie backs,
and other support systems and provisions for worker protection from hazards of
caving ground.
Methods and sequencing of installing excavation support.
Proposed locations for excavated materials.
Minimum lateral distance from the crest of slopes for vehicles, equipment, and
stockpiled materials.
Prevent surface water from entering excavations by grading, dikes, or other means.
Install excavation support and protection systems without damaging existing
buildings, structures, and site improvements adjacent to excavation.
Monitor vibrations, settlements, and movements.
1.4SUBMITTALS
Delegated-Design Submittal: For excavation support and protection system indicated to
comply with performance requirements and design criteria, including analysis data signed
and sealed by the qualified professional engineer, licensed to practice in the state where the
Project is constructed, responsible for their preparation.
1.5PROJECT CONDITIONS
Project-Site Information: A geotechnical report has been prepared for this Project and is
available for information only. The opinions expressed in this report are those of
geotechnical engineer and represent interpretations of subsoil conditions, tests, and results
of analyses conducted by geotechnical engineer. OWNER and ENGINEER will not be
responsible for interpretations or conclusions drawn from the data.
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Make additional test borings and conduct other exploratory operations necessary for
excavation support and protection.
The geotechnical report is referenced elsewhere in the Project Manual.
Survey Work: Engage a qualified land surveyor or professional engineer to survey adjacent
existing buildings, structures, and site improvements; establish exact elevations at fixed
points to act as benchmarks. Clearly identify benchmarks and record existing elevations.
During installation of excavation support and protection systems, regularly resurvey
benchmarks, maintaining an accurate log of surveyed elevations and positions for
comparison with original elevations and positions. Promptly notify ENGINEERif
changes in elevations or positions occur or if cracks, sags, or other damage is evident
in adjacent construction.
PRODUCTS (NOT USED)
EXECUTION
3.1PREPARATION
Protect structures, utilities, sidewalks, pavements, and other facilities from damage caused
by settlement, lateral movement, undermining, washout, and other hazards that could
develop during excavation supportand protection system operations.
Shore, support, and protect utilities encountered.
Install excavation support and protection systems to ensure minimum interference with
roads, streets, walks, and other adjacent occupied and used facilities.
Do not closeor obstruct streets, walks, or other adjacent occupied or used facilities
without permission from OWNER and authorities having jurisdiction. Provide alternate
routes around closed or obstructed traffic ways if required by authorities having
jurisdiction.
Locate excavation support and protection systems clear of permanent construction so that
forming and finishing of concrete surfaces are not impeded.
Monitor excavation support and protection systems daily during excavation progress and for
as long as excavation remains open. Promptly correct bulges, breakage, or other evidence
of movement to ensure that excavation support and protection systems remain stable.
Promptly repair damages to adjacent facilities caused by installing excavation support and
protection systems.
3.2TRENCHES
For excavations exceeding fivefeet in depth, provide adequate safety system meeting
requirements of applicable state and local construction safety orders, and Federal
requirements.
3.3REMOVAL AND REPAIRS
Remove excavation support and protection systems when construction has progressed
sufficiently to support excavation and bear soil and hydrostatic pressures. Remove in stages
to avoid disturbing underlying soils or damaging structures, pavements, facilities, and
utilities.
Fill voids immediately with approved backfill compacted to density specified in Section
31 20 00"Earthworks."
Repair or replace, as approved by ENGINEER, adjacent work damaged or displaced by
removing excavation support and protection systems.
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If the support or stability of existing structures or site improvements is dependent, leave
excavation support and protection systems permanently in place. Remove excavation
support and protection systems to a minimum depth of 48 inches below overlaying
construction and abandon remainder.
END OF SECTION
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SUPPORT AND PROTECTION.DOCX
SECTION 31 62 18
MICROPILES
PART 1 – GENERAL
1.1 SUMMARY
A. Section Includes:
1. The work of this section consists of constructing micropiles as shown on the contract
plans and approved working drawings and as specified herein. The micropile specialty
Contractor is responsible for furnishing all design, materials, products, accessories,
tools, equipment, services, transportation, labor and supervision, and manufacturing
techniques required for design, installation and testing of micropiles and pile top
attachments for this project.
2. The selected micropile Contractor shall select the micropile type, size, pile top
attachment, installation means and methods, estimate the ground-grout bond value
and determine the required bond length and final micropile diameter. The micropile
Contractor shall design and install micropiles that will develop the load capacities
indicated on the contract plans. The micropile load capacities shall be verified by
verification and proof load testing as required and must meet the test acceptance
criteria specified herein.
Where the imperative mood is used within this specification, “The Contractor shall” is
implied.
B. Unit Prices:
1. Measurement will be made as follows for the quantity, as specified, or directed by the
Engineer:
a. Mobilization will be measured on a lump-sum basis.
b. Micropiles will be measured per each, installed, and accepted.
c. Micropile verification load testing will be measured per each.
d. Micropile proof load testing will be measured per each.
2. The final pay quantities will be the design quantity increased or decreased by any
changes authorized by the Engineer.
3. Payment:
a. The quantities accepted for payment will be paid for at the contract unit prices
for the following items:
Pay Item Unit
Mobilization and Demobilization Lump Sum
Sacrificial Micropile Verification Load Test Each
Micropile Proof Load Test Each
Micropiles Lump Sum
b. The contract unit prices for the above items will be full and complete payment
for providing all design, materials, labor, equipment, and incidentals to complete
the work.
c. Where verification test piles are designated as sacrificial, the micropile
verification load test bid item shall include the cost of the sacrificial micropile.
d. The unit contract amount for “Micropiles” shall include the drilling, furnishing,
and placing the reinforcing steel and casing, grouting, and pile top attachments.
The micropile Contractor is also responsible for estimating the grout take. There
will be no extra payment for grout overruns.
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0537-038-01 MICROPILES (FHWA) JANUARY 2023
1.2 QUALITY ASSURANCE
A. Reference Standards:
1. American Association of State Highway and Transportation Officials (AASHTO):
a. AASHTO T26 Quality of Water to be Used in Concrete
b. AASHTO Standard Specifications for Highway Bridges
2. American Society for Testing and Materials (ASTM) International:
a. ASTM A36 Standard Specification for Carbon Structural Steel
b. ASTM A82 Cold-Drawn Steel Wire for Concrete Reinforcement
c. ASTM A252 Welded and Seamless Steel Pipe Piles
d. ASTM A572 Structural Steel
e. ASTM A615 Deformed and Plain Billet Steel Bars for Concrete Reinforcement
f. ASTM A722 Uncoated High-Strength Steel Bar for Prestressing Concrete
g. ASTM A775 Epoxy -Coated Reinforcing Steel Bars
h. ASTM A934 Epoxy-Coated Prefabricated Steel Reinforcing Bars
i. ASTM C33 Concrete Aggregates
j. ASTM C109 Compressive Strength of Hydraulic Cement Mortar
k. ASTM C144 Aggregate for Masonry Mortar
l. ASTM C188 Density of Hydraulic Cement
m. ASTM C150 Portland Cement
n. ASTM C494 Chemical Admixtures for Concrete
o. ASTM D1143 Method of Testing Piles Under Static Axial Compressive Load
p. ASTM D1784 Polyvinyl Chloride (PVC) Pipe (Class 13464-B)
q. ASTM D3350 Polyethylene Corrugated Tubing
r. ASTM D3689 Method of Testing Individual Piles Under Static Axial Tensile Load
s. ASTM D3966 Standard Test Method for Piles Under Lateral Load
3. American Welding Society (AWS):
a. AWS D1.1 Structural Welding Code-Steel
b. AWS D1.2 Structural Welding Code-Reinforcing Steel
4. American Petroleum Institute:
a. API 5CT (N-80) Specification for Casing and Tubing
b. API RP 13B-1 Recommended Practice – Standard Procedure for Field Testing
Water Based Drilling Fluids
5. Federal Highway Administration (FHWA):
a. FHWA NHI-05-039 Micropile Design and Construction
B. Qualifications:
1. Micropile Contractor’s Experience Requirements:
a. The micropile Contractor shall be experienced in the construction and load
testing of micropiles and have successfully constructed at least 5 projects in the
last 5 years involving construction totaling at least 100 micropiles of similar
capacity to those required in these plans and specifications.
b. The Contractor shall have previous micropile drilling and grouting experience in
soil/rock similar to project conditions. The Contractor shall submit construction
details, structural details, and load test results for at least three previous
successful micropile load tests from different projects of similar scope to this
project.
c. The Contractor shall assign an Engineer to supervise the work with experience
on at least 3 projects of similar scope to this project completed over the past 5
years. The Contractor shall not use consultants or manufacturers’
representatives to satisfy the supervising Engineer requirements of this section.
The on-site foremen and drill rig operators shall also have experience on at
PLUMMER ASSOCIATES, INC. 31 62 18 - Page 2 of 18 BID SET
0537-038-01 MICROPILES (FHWA) JANUARY 2023
least 3 projects over the past 5 years installing micropiles of equal or greater
capacity than required in these plans and specifications.
d. The micropiles shall be designed by a Professional Engineer licensed in Texas
with experience in the design of at least 3 successfully completed micropile
projects over the past 5 years, with micropiles of similar capacity to those
required in these plans and specifications. The micropile design engineer may
be either an employee of the Contractor or a separate Consultant design
engineer meeting the stated experience requirements.
1.3 DEFINITIONS
A. Admixture:
1. Substance added to the grout to control bleed and/or shrinkage, improve flowability,
reduce water content, or retard setting time.
B. Alignment Load (AL):
1. A minimum initial load (no greater than 10 percent of the Design Load) applied to
micropile during testing to keep the testing equipment correctly positioned.
C. Bond Length:
1. The length of the micropile that is bonded to the ground and used to transfer the
applied axial loads to the surrounding soil or rock.
D. Bond-breaker:
1. A sleeve placed over the steel reinforcement to prevent load transfer.
E. Casing:
1. Steel tube introduced during the drilling process in overburden soil to temporarily
stabilize the drill hole. This is usually withdrawn as the pile is grouted, although in
certain types of micropiles, some casing is permanently left in place to provide added
pile reinforcement.
F. Centralizer:
1. A device to support and position the reinforcing steel in the drill hole and/or casing so
that a minimum grout cover is provided.
G. Contractor:
1. The person/firm responsible for performing the micropile work.
H. Coupler:
1. The means by which load capacity can be transmitted from one partial length of
reinforcement to another.
I. Creep Movement:
1. The movement that occurs during the creep test of a micropile under a constant load.
J. Design Load (DL):
1. The maximum load expected to be applied to the micropile during its service life.
K. Encapsulation:
1. A corrugated or deformed tube protecting the reinforcing steel against corrosion.
L. Engineer:
1. The Owner or Owner’s authorized agent.
M. Free (unbonded) length:
1. The designed length of the micropile that is not bonded to the surrounding ground or
grout.
N. Micropile:
1. A small-diameter, bored, cast-in-place composite pile, in which the applied load is
resisted by steel reinforcement, cement grout and frictional grout/ground bond.
O. Maximum Test Load:
1. The maximum load to which the micropile is subjected during testing.
P. Ultimate Grout-to-Ground Bond Values:
1. The estimated ultimate geotechnical unit grout- to-ground bond strength selected for
use in design.
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0537-038-01 MICROPILES (FHWA) JANUARY 2023
Q. Overburden:
1. Material, natural or placed, that may require cased drilling methods to provide an
open borehole to underlying strata.
R. Post-grouting:
1. The injection of additional grout into the load transfer length of a micropile after the
primary grout has set. Also known as regrouting or secondary grouting.
S. Primary Grout:
1. Portland-cement-based grout injected into the micropile hole prior to or after the
installation of the reinforcement to direct the load transfer to the surrounding ground
along the micropile.
T. Proof Load Test:
1. Incremental loading of a production micropile, recording the total movement at each
increment.
U. Reinforcement:
1. The steel component of the micropile that accepts and/or resists applied loadings.
V. Sheathing:
1. Smooth or corrugated piping or tubing that protects the reinforcing steel against
corrosion.
W. Spacer:
1. A device to separate elements of a multiple-element reinforcement.
X. Verification Load Test:
Pile load test performed to verify the design of the pile system and the construction
methods proposed, prior to installation of production piles.
1.4 AVAILABLE INFORMATION
A. Available information developed by the Owner, or by the Owner’s duly authorized
representative include the following items:
1. Plans prepared by HDR Engineering, Inc., dated January 25, 2023Geotechnical Report
by Rock Engineering & Testing Laboratory, Inc. (RETL), titled “Geotechnical
Supplement No. 1, Subsurface Investigation, Laboratory Testing Program, and
Additional Foundation Recommendations for the Proposed Broadway WWTP
Rehabilitation (18084A)”, dated March 22, 2022. RETL Job No. G121393SA1.
1.5 CONSTRUCTION SITE SURVEY
A. Before bidding the Work, the Contractor shall review the available subsurface information
and visit the site to assess the site geometry, equipment access conditions, and location of
existing structures and above ground facilities.
B. The Contractor is responsible for field locating and verifying the location of all utilities shown
on the plans prior to starting the Work. Maintain uninterrupted service for those utilities
designated to remain in service throughout the Work. Notify the Engineer of any utility
locations different from shown on the plans that may require micropile relocations or
structure design modification. Subject to the Engineer’s approval, additional cost to the
Contractor due to micropile relocations and/or structure design modification resulting from
utility locations different from shown on the plans, will be paid as Extra Work.
C. Prior to start of any micropile construction activity, the Contractor and Engineer shall jointly
inspect the site to observe and document the pre-construction condition of the site, existing
structures, and facilities.
1.6 MICROPILE DESIGN REQUIREMENTS
A. The micropiles shall be designed to meet the specified loading conditions, as shown on the
contract plans and approved working drawings. Design the micropiles and pile top to pile
cap connections using the procedures contained in FHWA NHI-05-039.
B. The required geotechnical factors of safety shall be in accordance with the FHWA manual,
unless specified otherwise. Estimated soil/rock design shear strength parameters, unit
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0537-038-01 MICROPILES (FHWA) JANUARY 2023
weights, applied foundation loadings, slope and external surcharge loads, corrosion
protection requirements, known utility locations, easements, rights-of-way, and other
applicable design criteria will be as shown on the plans or specified herein.
C. Structural design of any individual micropile structure elements not covered in the FHWA
manual shall be by the service load design method in conformance with appropriate articles
of the most current Edition of the AASHTO Standard Specifications for Highway Bridges,
including current interim specifications.
D. Where required as shown on the contract plans, corrosion protection of the internal steel
reinforcing bars, consisting of either encapsulation, epoxy coating, or grout, shall be
provided in accordance with Materials Section 2.0. Where permanent casing is used for a
portion of the micropile, encapsulation shall extend at least 5 feet into the casing.
1.7 SUBMITTALS
A. See Specification Section 01 33 00 for requirements for the mechanics and administration of
the submittal process.
B. Qualifications Submittals:
1. At least 45 calendar days before the planned start of micropile construction, the
Contractor shall submit a completed project reference list and a personnel list. The
completed project reference list shall include a brief project description with the
owner's name and current phone number and load test reports. The personnel list
shall identify the micropile system design engineer (if applicable), supervising project
Engineer, drill rig operators, and on-site foremen to be assigned to the project. The
personnel list shall contain a summary of each individual's experience and be
complete enough for the Engineer to determine whether each individual satisfies the
required qualifications. The Engineer will approve or reject the Contractor's
qualifications within 15 calendar days after receipt of a complete submission.
Additional time required due to incomplete or unacceptable submittals will not be
cause for time extension or impact or delay claims. All costs associated with
incomplete or unacceptable submittals shall be borne by the Contractor.
2. Work shall not be started, nor materials ordered, until the Engineer’s written approval
of the Contractor's experience qualifications is given. The Engineer may suspend the
Work if the Contractor uses non-approved personnel. If work is suspended, the
Contractor shall be fully liable for all resulting costs and no adjustment in contract
time will result from the suspension.
C. Design Submittals:
1. At least 21 calendar days before the planned start of micropile structure construction,
submit complete design calculations and working drawings to the Engineer for review
and approval. Include all details, dimensions, quantities, ground profiles, and cross-
sections necessary to construct the micropile structure. Verify the limits of the
micropile structure and ground survey data before preparing the detailed working
drawings.
2. The drawings and calculations shall be signed and sealed by the contractor’s
Professional Engineer or by the Consultant designer’s Professional Engineer (if
applicable), previously approved by the owner’s Engineer. If the micropile contractor
uses a consultant design engineer to prepare the design, the micropile contractor
shall still have overall contract responsibility for both the design and the construction.
D. Design calculations shall include, but not be limited to, the following items:
1. A written summary report which describes the overall micropile design.
2. Applicable code requirements and design references.
3. Micropile structure critical design cross-section(s) geometry including soil/rock strata
and piezometric levels and location, magnitude and direction of design applied
loadings, including slope or external surcharge loads.
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4. Design criteria including, soil/rock shear strengths (friction angle and cohesion), unit
weights, and ground-grout bond values and micropile drillhole diameter assumptions
for each soil/rock strata.
5. Factors of safety and allowable stresses used in the design on the ground-grout bond
values, surcharges, soil/rock and material unit weights, steel, grout, and concrete
materials.
6. Seismic design earthquake acceleration coefficient.
7. Design calculation sheets (both static and seismic) with the project number, micropile
structure location, designation, date of preparation, initials of designer and checker,
and page number at the top of each page. Provide an index page with the design
calculations.
8. Design notes including an explanation of any symbols and computer programs used in
the design.
9. Pile to pile cap connection calculations.
E. The working drawings shall include all information required for the construction and quality
control of the piling. Working drawings shall include, but not be limited to, the following
items unless provided in the contract plans:
1. A plan view of the micropile structure(s) identifying:
a. A reference baseline and elevation datum.
b. The offset from the construction centerline or baseline to the face of the
micropile structure at all changes in horizontal alignment.
c. Beginning and end of micropile structure stations.
d. Right-of-way and permanent or temporary construction easement limits,
location of all known active and abandoned existing utilities, adjacent
structures, or other potential interferences. The centerline of any drainage
structure or drainage pipe behind, passing through, or passing under the
micropile structure.
e. Subsurface exploration locations shown on a plan view of the proposed
micropile structure alignment with appropriate reference base lines to fix the
locations of the explorations relative to the micropile structure.
2. An elevation view of the micropile structure(s) identifying:
a. Elevation view showing micropile locations and elevations; vertical and
horizontal spacing; batter and alignment and the location of drainage elements
(if applicable).
b. Existing and finish grade profiles both behind and in front of the micropile
structure.
3. Design parameters and applicable codes.
4. General notes for constructing the micropile structure including construction
sequencing or other special construction requirements.
5. Horizontal and vertical curve data affecting the micropile structure and micropile
structure control points. Match lines or other details to relate micropile structure
stationing to centerline stationing.
6. A listing of the summary of quantities on the elevation drawing of each micropile
structure showing pay item estimated quantities.
7. Micropile typical sections including micropile spacing and inclination; minimum
drillhole diameter; pipe casing and reinforcing bar sizes and details; splice types and
locations; centralizers and spacers; grout bond zone and casing plunge lengths (if
used); corrosion protection details; and connection details to the pile cap, anchorage,
plates, etc.
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8. A typical detail of verification and production proof test micropiles defining the
micropile length, minimum drillhole diameter, inclination, and load test bonded and
unbonded test lengths.
9. Details, dimensions, and schedules for all micropiles, casing and reinforcing steel,
including reinforcing bar bending details.
10. Details for constructing micropile structures around drainage facilities (if applicable).
F. The working drawings and design calculations shall be signed and sealed by the Contractor’s
Professional Engineer. If the micropile Contractor uses a Consultant design engineer to
prepare the design, the micropile Contractor shall still have overall contract responsibility for
both the design and the construction.
G. Submit one electronic (Adobe or Bluebeam .pdf) copy of working drawings to Engineer for
review. Drawing sheet size shall be 11in. x 17in. A marked electronic (Adobe or Bluebeam
.pdf) copy will be returned with any indicated corrections. The Engineer will approve or
reject the Contractor's submittal within 21 days after receipt of a complete submission. If
revisions are necessary, make the necessary corrections and resubmit one electronic copy.
When the drawings are approved, furnish one final electronic copy of the approved
drawings. The Contractor will not be allowed to begin micropile structure construction or
incorporate materials into the work until the submittal requirements are satisfied and found
acceptable to the Engineer. Changes or deviations from the approved submittals must be re-
submitted for approval. No adjustments in contract time or delay or impact claims will be
allowed due to incomplete submittals.
H. Revise the drawings when plan dimensions are changed due to field conditions or for other
reasons. Within 30 days after completion of the work, submit as-built drawings to the
Engineer. Provide revised design calculations signed by the approved Registered
Professional Engineer for all design changes made during the construction of the micropile
structure.
I. Construction Submittals: The Contractor shall prepare and submit to the Engineer, for
review of completeness, one electronic copy of the following for the micropile system or
systems to be constructed:
1. Detailed step-by-step description of the proposed micropile construction procedure,
including personnel, testing and equipment to assure quality control. This step-by-
step procedure shall be shown on the working drawings in sufficient detail to allow
the Engineer to monitor the construction and quality of the micropiles.
2. Proposed start date and time schedule and micropile installation schedule providing
the following:
a. Micropile number
b. Micropile design load
c. Type and size of reinforcing steel
d. Minimum bond length
e. Total micropile length
f. Micropile top pile cap attachment
3. If welding of casing is proposed, submit the proposed welding procedure, certified by
a qualified welding specialist.
4. Information on headroom and space requirements for installation equipment that
verify the proposed equipment can perform at the site.
5. Plan describing how surface water, drill flush, and excess waste grout will be
controlled and disposed.
6. Certified mill test reports for the reinforcing steel or coupon test results for permanent
casing without mill certification. The ultimate strength, yield strength, elongation, and
material properties composition shall be included. For API N-80 pipe casing, coupon
test results may be submitted in lieu of mill certification.
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7. Proposed Grouting Plan. The grouting plan shall include complete descriptions,
details, and supporting calculations for the following:
a. Grout mix design and type of materials to be used in the grout including
certified test data and trial batch reports.
b. Methods and equipment for accurately monitoring and recording the grout
depth, grout volume and grout pressure as the grout is being placed.
c. Grouting rate calculations, when requested by the Engineer. The calculations
shall be based on the initial pump pressures or static head on the grout and
losses throughout the placing system, including anticipated head of drilling fluid
(if applicable) to be displaced.
d. Estimated curing time for grout to achieve specified strength. Previous test
results for the proposed grout mix completed within one year of the start of
grouting may be submitted for initial verification and acceptance and start of
production work. During production, grout shall be tested in accord with
Section 3.4.5.
e. Procedure and equipment for Contractor monitoring of grout quality.
8. Detailed plans for the proposed micropile load testing method. This shall include all
drawings, details, and structural design calculations necessary to clearly describe the
proposed test method, reaction load system capacity and equipment setup, types,
and accuracy of apparatus to be used for applying and measuring the test loads and
pile top movements in accordance with Section 3.6, Pile Load Tests.
9. Calibration reports and data for each test jack, pressure gauge and master pressure
gauge and electronic load cell to be used. The calibration tests shall have been
performed by an independent testing laboratory, and tests shall have been performed
within 90 calendar days of the date submitted. Testing shall not commence until the
Engineer has reviewed and accepted the jack, pressure gauge, master pressure
gauge and electronic load cell calibration data.
10. Work other than test pile installation shall not begin until the construction submittals
have been received, reviewed, and accepted in writing by the Engineer. Provide
submittal items (a) through (e) at least 21 calendar days prior to initiating micropile
construction, item (g) as the work progresses for each delivery and submittal items
(f), (h), and (i) at least 7 days prior to start of micropile load testing or incorporation
of the respective materials into the work. The Contractor shall allow the Engineer 7
calendar days to review the construction submittals after a complete set has been
received. Additional time required due to incomplete or unacceptable submittals shall
not be cause for delay or impact claims. All costs associated with incomplete or
unacceptable Contractor submittals shall be the responsibility of the Contractor.
1.8 PRE-CONSTRUCTION MEETING
A pre-construction meeting will be scheduled by the Engineer and held prior to the start of
micropile construction. The Engineer, prime Contractor, micropile specialty Contractor, micropile
design engineer, excavation Contractor and geotechnical instrumentation specialist (if applicable)
shall attend the meeting. Attendance is mandatory. The pre-construction meeting will be conducted
to clarify the construction requirements for the work, to coordinate the construction schedule and
activities, and to identify contractual relationships and delineation of responsibilities amongst the
prime Contractor and the various Subcontractors - specifically those pertaining to excavation for
micropile structures, anticipated subsurface conditions, micropile installation and testing, micropile
structure survey control and site drainage control.
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PART 2 – PRODUCTS
2.1 MATERIALS
A. Furnish materials new and without defects. Remove defective materials from the jobsite at
no additional cost. Materials for micropiles shall consist of the following:
1. Admixtures for Grout:
a. Admixtures shall conform to the requirements of ASTM C494.
b. Admixtures that control bleed, improve flowability, reduce water content, and
retard set may be used in the grout, subject to the review and acceptance of
the Engineer.
c. Admixtures shall be compatible with the grout and mixed in accordance with
the manufacturer’s recommendations.
d. Expansive admixtures shall only be added to the grout used for filling sealed
encapsulations and anchorage covers. Accelerators are not permitted.
Admixtures containing chlorides are not permitted.
2. Cement:
a. All cement shall be Portland cement conforming to ASTM C150, Types I, II, III
or V.
3. Centralizers and Spacers:
a. Centralizers and spacers shall be fabricated from schedule 40 PVC pipe or
tube, steel, or material non-detrimental to the reinforcing steel.
b. Wood shall not be used.
4. Encapsulation:
a. Encapsulation (double corrosion protection) shall be shop fabricated using high-
density, corrugated polyethylene tubing conforming to the requirements of
ASTM D3350 with a nominal wall thickness of 0.8 mm.
b. The inside annulus between the reinforcing bars and the encapsulating tube
shall be a minimum of 5mm and be fully grouted with non-shrink grout
conforming to Materials Section 2.0.
5. Fine Aggregate:
a. If sand - cement grout is used, sand shall conform to ASTM C144.
6. Galvanization:
a. If used, galvanization shall meet the requirements of ASTM A153.
7. Grout:
Neat cement or sand/cement mixture with a minimum 3-day compressive
strength of 2,000 psi and a 28-day compressive strength of 4,000 psi per ASTM
C109.
8. Permanent Casing Pipe:
a. Permanent steel casing/pipe shall have the diameter and at least minimum wall
thickness shown on the approved Working Drawings. The permanent steel
casing/pipe:
1) shall extend a minimum distance of 15’ from the top of the pile.
2) shall meet the Tensile Requirements of ASTM A252, Grade 3, except the
yield strength shall be a minimum of 50 ksi to 80 ksi as used in the
design submittal.
3) may be new "Structural Grade" (a.k.a. "Mill Secondary" ) steel pipe
meeting above but without Mill Certification, free from defects (dents,
cracks, tears) and with two coupon tests per truckload delivered to the
fabricator.
4) Shall be coated with a 16 MIL DFT coating of coal tar epoxy.
B. For permanent casing/pipe that will be welded for structural purposes, the following material
conditions apply:
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1. the carbon equivalency (CE) as defined in AWS D1.l, Section XI5.1, shall not exceed
0.45, as demonstrated by mill certifications
2. the sulfur content shall not exceed 0.05%, as demonstrated by mill certifications
C. For permanent casing/pipe that will be shop or field welded, the following fabrication or
construction conditions apply:
1. the steel pipe shall not be joined by welded lap splicing
2. welded seams and splices shall be complete penetration welds
3. partial penetration welds may be restored in conformance with AWS D1.1
4. the proposed welding procedure certified by a welding specialist shall be submitted
for approval
5. Threaded casing joints shall develop at least the required compressive, tensile, and/or
bending strength used in the design of the micropile.
D. Plates and Shapes:
1. Structural steel plates and shapes for pile top attachments shall conform to ASTM A
36, or ASTM A 572, Grade 50.
E. Reinforcing Bars:
1. Reinforcing steel shall be deformed bars in accordance with ASTM:
a. A 615, Grade 60 or Grade 75, or ASTM A 722, Grade 150.
b. When a bearing plate and nut are required to be threaded onto the top end of
reinforcing bars for the pile top to footing anchorage, the threading may be
continuous spiral deformed ribbing provided by the bar deformations (e.g.,
Dywidag or Williams continuous threadbars) or may be cut into a reinforcing bar.
c. If threads are cut into a reinforcing bar, the next larger bar number designation
from that shown on the Plans shall be provided, at no additional cost.
d. Bar tendon couplers, if required, shall develop the ultimate tensile strength of
the bars without evidence of any failure.
F. Sheathing:
1. Smooth plastic sheathing, including joints, shall be watertight. Polyvinyl chloride (PVC)
sheathing shall conform to ASTM D 1784, Class 13464-B.
G. Water:
1. Water used in the grout mix shall conform to AASHTO T 26 and shall be potable, clean,
and free from substances that may be injurious to cement and steel.
PART 3 – EXECUTION
3.1 SITE DRAINAGE CONTROL
The Contractor shall control and properly dispose of drill flush and construction related waste,
including excess grout, in accord with the standard specifications and all applicable local codes and
regulations. Provide positive control and discharge of all surface water that will affect construction
of the micropile installation. Maintain all pipes or conduits used to control surface water during
construction. Repair damage caused by surface water at no additional cost. Upon substantial
completion of the Work, remove surface water control pipes or conduits from the site. Alternatively,
with the approval of the Engineer, pipes or conduits that are left in place, may be fully grouted and
abandoned or left in a way that protects the structure and all adjacent facilities from migration of
fines through the pipe or conduit and potential ground loss.
Immediately contact the Engineer if unanticipated existing subsurface drainage structures are
discovered during excavation or drilling. Suspend work in these areas until remedial measures
meeting the Engineer’s approval are implemented. Cost of remedial measures or repair work
resulting from encountering unanticipated subsurface drainage structures, will be paid for as Extra
Work.
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3.2 EXCAVATION
Coordinate the work and the excavation so the micropile structures are safely constructed. Perform
the micropile construction and related excavation in accordance with the Plans and approved
submittals. No excavations steeper than those specified herein or shown on the Plans will be made
above or below the micropile structure locations without written approval of the Engineer.
3.3 MICROPILE ALLOWABLE CONSTRUCTION TOLERANCES
A. Centerline of piling shall not be more than 3 inches from indicated plan location. The micro-pile
casing shall be designed to withstand this potential eccentricity and its resulting P-D effect.
5
B. Pile shall be plumb within 2 percent of total-length plan alignment.
C. Top elevation of pile shall be within plus 1 inch - minus 2 inches maximum from vertical
elevation indicated.
D. Centerline of reinforcing steel shall not be more than 0.75 inch from indicated location.
3.4 MICROPILE INSTALLATION
The micropile Contractor shall select the drilling method, the grouting procedure, and the grouting
pressure used for the installation of the micropiles. The micropile Contractor shall also determine
the micropile casing size, final drillhole diameter and bond length, and central reinforcement steel
sizing necessary to develop the specified load capacities and load testing requirements. The
micropile Contractor is also responsible for estimating the grout take. There will be no extra
payment for grout overruns.
A. Drilling:
1. The drilling equipment and methods shall be suitable for drilling through the
conditions to be encountered, without causing damage to any overlying or adjacent
structures or services. The drillhole must be open along its full length to at least the
design minimum drillhole diameter prior to placing grout and reinforcement.
2. Vibratory pile driving hammers shall not be used to advance casing.
3. Temporary casing or other approved method of pile drillhole support will be required
in caving or unstable ground to permit the pile shaft to be formed to the minimum
design drillhole diameter. The Contractor’s proposed method(s) to provide drillhole
support and to prevent detrimental ground movements shall be reviewed by the
Engineer. Detrimental ground movement is defined as movement which requires
remedial repair measures. Use of drilling fluid containing bentonite is not allowed.
4. Costs of removal or remedial measures due to encountering unanticipated subsurface
obstructions will be paid for as Extra Work.
B. Ground Heave or Subsidence:
1. During construction, the Contractor shall observe the conditions in the vicinity of the
micropile construction site daily for signs of ground heave or subsidence.
2. Immediately notify the Engineer if signs of movements are observed.
3. Contractor shall immediately suspend or modify drilling or grouting operations if
ground heave or subsidence is observed, if the micropile structure is adversely
affected, or if adjacent structures are damaged from the drilling or grouting.
4. If the Engineer determines that the movements require corrective action, the
Contractor shall take corrective actions necessary to stop the movement or perform
repairs.
5. When due to the Contractor’s methods or operations or failure to follow the
specified/approved construction sequence, as determined by the Engineer, the costs
of providing corrective actions will be borne by the Contractor.
6. When due to differing site conditions, as determined by the Engineer, the costs of
providing corrective actions will be paid as Extra Work.
C. Pipe Casing and Reinforcement Placement and Splicing:
1. Reinforcement shall be placed before temporary casing is withdrawn.
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2. Reinforcement surface shall be free of deleterious substances such as soil, mud,
grease, or oil that might contaminate the grout or coat the reinforcement and impair
bond.
3. Pile cages and reinforcement groups, if used, shall be sufficiently robust to withstand
the installation and grouting process and the withdrawal of the drill casings without
damage or disturbance.
4. The Contractor shall check pile top elevations and adjust all installed micropiles to the
planned elevations.
5. Centralizers and spacers shall be provided at a maximum spacing of 10 feet.
6. The upper and lower most centralizer shall be located no more than 5 feet from the
top and bottom of the micropile.
7. Centralizers and spacers shall permit the free flow of grout without misalignment of
the reinforcing bar(s) and permanent casing.
8. The central reinforcement bars with centralizers shall be lowered into the stabilized
drillhole and set. The reinforcing steel shall be inserted into the drill hole to the
desired depth without difficulty. Partially inserted reinforcing bars shall not be driven
or forced into the hole. Contractor shall redrill and reinsert reinforcing steel when
necessary to facilitate insertion.
9. Lengths of casing and reinforcing bars to be spliced shall be secured in proper
alignment and in a manner to avoid eccentricity or angle between the axes of the two
lengths to be spliced. Splices and threaded joints shall meet the requirements of
Materials Section 2.0. Threaded pipe casing joints shall be located at least two casing
diameters (OD) from a splice in any reinforcing bar. When multiple bars are used, bar
splices shall be staggered at least 1 foot.
D. Grouting:
1. Micropiles shall be primary grouted the same day the load transfer bond length is
drilled. The Contractor shall use a stable neat cement grout or a sand cement grout
with a minimum 28- day unconfined compressive strength of 4,000 psi. Admixtures,
if used, shall be mixed in accordance with manufacturer’s recommendations. The
grouting equipment used shall produce a grout free of lumps and undispersed
cement. The Contractor shall have means and methods of measuring the grout
quantity and pumping pressure during the grouting operations. The grout pump shall
be equipped with a pressure gauge to monitor grout pressures. A second pressure
gauge shall be placed at the point of injection into the pile top. The pressure gauges
shall be capable of measuring pressures of at least 150 psi or twice the actual grout
pressures used, whichever is greater. The grout shall be kept in agitation prior to
mixing. Grout shall be placed within one hour of mixing. The grouting equipment shall
be sized to enable each pile to be grouted in one continuous operation.
2. The grout shall be injected from the lowest point of the drill hole and injection shall
continue until uncontaminated grout flows from the top of the pile. The grout may be
pumped through grout tubes, casing, hollow-stem augers, or drill rods. Temporary
casing, if used, shall be extracted in stages ensuring that, after each length of casing
is removed the grout level is brought back up to the ground level before the next
length is removed. The tremie pipe or casing shall always extend below the level of
the existing grout in the drillhole. The grout pressures and grout takes shall be
controlled to prevent excessive heave or fracturing of rock or soil formations. Upon
completion of grouting, the grout tube may remain in the hole, but must be filled with
grout.
3. Grout within the micropiles shall be allowed to attain the required design strength
prior to being loaded.
4. If the Contractor elects to use a post grouting system, Working Drawings and details
shall be submitted to the Engineer for review in accordance with Section 1.8, Pre-
installation Submittals.
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E. Grout Testing:
1. Grout within the micropile verification and proof test piles shall attain the minimum
required 3-day compressive strength of 2,000 psi prior to load testing. Previous test
results for the proposed grout mix completed within one year of the start of work may
be submitted for initial verification of the required compressive strengths for
installation of pre-production verification test piles and initial production piles. During
production, micropile grout shall be tested by the Contractor for compressive strength
in accordance with ASTM C109 at a frequency of no less than one set of three 2-inch
grout cubes from each grout plant each day of operation or per every 10 piles,
whichever occurs more frequently. The compressive strength shall be the average of
the 3 cubes tested.
2. Grout consistency as measured by grout density shall be determined by the
Contractor per ASTM C 188 or API RP-13B-1 at a frequency of at least one test per
pile, conducted just prior to start of pile grouting. The Baroid Mud Balance used in
accordance with API RP-13B-1 is an approved device for determining the grout
density of neat cement grout. The measured grout density shall be between 145
lb/ft3 and 150 lb/ft3.
3. Grout samples shall be taken directly from the grout plant. Provide grout cube
compressive strength and grout density test results to the Engineer within 24 hours of
testing.
3.5 MICROPILE INSTALLATION RECORDS:
Contractor shall prepare and submit to the Engineer full-length installation records for each
micropile installed. The records shall be submitted within one work shift after that pile installation is
completed. The data shall be recorded on the micropile installation log. A separate log shall be
provided for each micropile.
3.6 PILE LOAD TESTS
Perform verification and proof testing of piles at the locations specified herein or designated by
the Engineer. Perform tension load testing in accordance with ASTM D3689, except as modified
herein. The following pile load tests shall be performed:
Location Verification Tests Proof Tests
Aeration Basin Effluent
2 2
Chamber
A. Verification Load Tests:
1. Perform pre-production verification pile load testing to verify the design of the pile
system and the construction methods proposed prior to installing any production
piles.
a. Two (2) sacrificial verification test piles shall be constructed in conformance
with the approved Working Drawings. Verification test pile(s) shall be installed
at the following locations:
b. Two (2) east of Elevated Effluent Trough. Coordinate locations with the
Engineer.
2. Verification load tests shall be performed to verify that the Contractor installed
micropiles will meet the required compression load capacities and load test
acceptance criteria and to verify that the length of the micropile bond zone is
adequate. The micropile verification load test results must verify the Contractor's
design and installation methods and be reviewed and accepted by the Engineer prior
to beginning installation of production micropiles.
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3. The drilling-and-grouting method, casing length and outside diameter, reinforcing bar
lengths, and depth of embedment for the verification test pile(s) shall be identical to
those specified for the production piles at the given locations. The verification test
micropile structural steel sections shall be sized to safely resist the maximum test
load.
4. The maximum verification and proof test loads applied to the micropile shall not
exceed 80 percent of the structural capacity of the micropile structural elements, to
include steel yield in tension, steel yield or buckling in compression, or grout crushing
in compression. Any required increase in strength of the verification test pile elements
above the strength required for the production piles shall be provided for in the
contractor’s bid price.
5. The jack shall be positioned at the beginning of the test such that unloading and
repositioning during the test will not be required.
B. Testing Equipment and Data Recording:
1. Testing equipment shall include:
a. dial gauges
b. dial gauge support
c. jack and pressure gauge
d. electronic load cell
e. a reaction frame
2. The load cell is required only for the creep test portion of the verification test.
3. The contractor shall provide a description of test setup and jack, pressure gauge and
load cell calibration curves in accordance with the Submittals Section.
4. Design the testing reaction frame to be sufficiently rigid and of adequate dimensions
such that excessive deformation of the testing equipment does not occur. Align the
jack, bearing plates, and stressing anchorage such that unloading and repositioning of
the equipment will not be required during the test.
5. Apply and measure the test load with a hydraulic jack and pressure gauge. The
pressure gauge shall be graduated in 75 psi increments or less. The jack and pressure
gauge shall have a pressure range not twice the anticipated maximum test pressure.
Jack ram travel shall be sufficient to allow the test to be done without resetting the
equipment. Monitor the creep test load hold during verification tests with both the
pressure gauge and the electronic load cell. Use the load cell to accurately maintain a
constant load hold during the creep test load hold increment of the verification test.
6. Measure the pile top movement with a dial gauge capable of measuring to 0.001 inch.
The dial gauge shall have a travel sufficient to allow the test to be done without
having to reset the gauge. Visually align the gauge to be parallel with the axis of the
micropile and support the gauge independently from the jack, pile, or reaction frame.
Use a minimum of two dial gauges when the test setup requires reaction against the
ground or single reaction piles on each side of the test pile.
7. The required load test data shall be recorded by the geotechnical instrumentation
specialist and witnessed by the Engineer.
C. Verification Test Loading Schedule:
1. Test verification piles designated for compression or tension load testing to a
maximum test load of 2.0 times the micropile Design Load shown on the Plans or
Working Drawings.
2. The verification pile load tests shall be made by incrementally loading the micropile in
accordance with the following cyclic load schedule for both compression and tension
loading:
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Step Loading Applied Load Hold Time (min.)
1 Apply AL 2.5
0.15 DL 2.5
2 Cycle 1 0.30 DL 2.5
0.45 DL 2.5
AL 1
0.15 DL 1
0.30 DL 1
0.45 DL 2.5
3 Cycle 2 0.60 DL 2.5
0.75 DL 2.5
0.90 DL 2,5
1.00 DL 2.5
AL 1
0.15 DL 1
1.00 DL 1
4 Cycle 3 1.15 DL 2.5
1.30 DL 10 to 60 minutes
1.45 DL 2.5
AL 1
0.15DL1
1.45 DL 1
1.60 DL 1
1.75 DL 2.5
5 Cycle 4 1.90 DL 2.5
2.00 DL 10
1.50 DL 5
1.00 DL 5
0.50 DL 5
AL 5
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3. Pile top movement shall be measured at each load increment. The load-hold period
shall start as soon as each test load increment is applied. The verification test pile
shall be monitored for creep at the 1.30 Design Load (DL). Pile movement during the
creep test shall be measured and recorded at 1, 2, 3, 4, 5, 6, 10, 20, 30, 50, and 60
minutes. The alignment load shall not exceed 5 percent of the DL load. Dial gauges
shall be reset to zero after the initial AL is applied.
4. The acceptance criteria for micropile verification load tests are:
a. The pile shall sustain the first compression 1.0 DL test load with no more than
1/8 inch total vertical movement at the top of the pile, relative to the position
of the top of the pile prior to testing.
b. At the end of the 1.30 DL creep test load increment, test piles shall have a
creep rate not exceeding 0.04 inch/log cycle time (1 to 10 minutes) or 0.08
inch/log cycle time (6 to 60 minutes or the last log cycle if held longer). The
creep rate shall be linear or decreasing throughout the creep load hold period.
c. Failure does not occur at the 2.0 DL maximum test load. Failure is defined as
load where the slope of the load versus head settlement curve first exceeds
0.025 in/K.
5. The Engineer will provide the Contractor written confirmation of the micropile design
and construction within 3 working days of receipt of the verification load test results.
This written confirmation will either confirm the capacities and bondlengths specified
in the Working Drawings for micropiles or reject the piles based upon the verification
test results.
D. Verification Test Pile Rejection:
1. If a verification-tested micropile fails to meet the acceptance criteria, the Contractor
shall modify the design, the construction procedure, or both. These modifications may
include modifying the installation methods, increasing the bond length, or changing
the micropile type. Any modification that necessitates changes to the structure shall
require the Engineer’s prior review and acceptance. Any modifications of design or
construction procedures or cost of additional verification test piles and load testing
shall be at the Contractor’s expense. At the completion of verification testing, test
piles shall be removed down to the elevation specified by the Engineer.
E. Proof Load Tests:
1. Perform proof load tests on the first set of production piles installed at each
designated substructure unit prior to the installation of the remaining production piles
in that unit. The first set of production piles is the number required to provide the
required reaction capacity for the proof tested pile. Refer to Article 3.6 for the number
of required proof tests.
F. Proof Test Loading Schedule:
1. Test piles designated for compression or tension proof load testing to a maximum test
load of 1.60 times the micropile Design Load shown on the Plans or Working
Drawings. Proof tests shall be made by incrementally loading the micropile in
accordance with the following schedule, to be used for both compression and tension
loading:
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Step Loading Applied Load Hold Time (min.)
1 Apply AL 2.5
0.15 DL 2.5
0.30 DL 2.5
0.45 DL 2.5
0.60 DL 2.5
0.75 DL 2.5
2 Load Cycle 0.90 DL 2.5
1.00 DL 2.5
1.15 DL 2.5
1.30 DL 10 to 60 minutes
1.45 DL 2.5
1.60 DL 2.5
1.30 DL 4
1.00 DL 4
3 Unload Cycle 0.75 DL 4
0.50 DL 4
0.25 DL 4
AL 4
2. Depending on performance, either a 10 minute or 60-minute creep test shall be
performed at the 1.30DL Test Load. Where the pile top movement between 1 and 10
minutes exceeds 1 mm, the Maximum Test Load shall be maintained an additional 50
minutes. Movements shall be recorded at 1, 2, 3, 5, 6, 10, 20, 30, 50 and 60 minutes.
The alignment load shall not exceed 5 percent of DL. Dial gauges shall be reset to
zero after the initial AL is applied. The acceptance criteria for micropile proof load
tests are:
a. The pile shall sustain the compression or tension 1.0 DL test load with no more
than 1/8_inch total vertical movement at the top of the pile, relative to the
position of the top of the pile prior to testing.
b. At the end of the 1.30DL creep test load increment, test piles shall have a
creep rate not exceeding 1 mm/log cycle time (1 to 10 minutes) or 2 mm/log
cycle time (6 to 60 minutes). The creep rate shall be linear or decreasing
throughout the creep load hold period.
c. Failure does not occur at the 1.60DL maximum test load. Failure is defined as
load where the slope of the load versus head settlement curve first exceeds
0.025 in/K.
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G. Proof Test Pile Rejection:
1. If a proof-tested micropile fails to meet the acceptance criteria, the Contractor shall
immediately proof test another micropile within that footing. For failed piles and
further construction of other piles, the Contractor shall modify the design, the
construction procedure, or both. These modifications may include installing
replacement micropiles, incorporating piles at not more than 50% of the maximum
load attained, post grouting, modifying installation methods, increasing the bond
length, or changing the micropile type. Any modification that necessitates changes to
the structure design shall require the Engineer’s prior review and acceptance. Any
modifications of design or construction procedures, or cost of additional verification
test piles and verification and/or proof load testing, or replacement production
micropiles, shall be at the Contractor’s expense.
END OF SECTION
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SECTION 31 63 29
DRILLED PIERS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Drilled piers.
B. Related Specification Sections include but are not necessarily limited to:
1. Section 03 00 05 - Concrete.
C. Unit Prices:
1. Measurement:
a. Length of drilled piers for payment to be measured from tip to cut off
elevation.
b. Any drilled pier length extending above cut off elevation indicated will
not be measured for payment.
c. Drilled pier lengths extending below authorized tip elevation will not be
measured for payment.
2. Payment:
a. Contract bid price for piling to be based on the total number, length,
and diameter of drilled piers, and reinforcing steel indicated on
Drawings.
b. Bid price to include all costs for drilled pier drilling; excavation for bells;
removing excavated material; furnishing, placing, and removing casing
where required; dewatering where necessary; furnishing and placing
concrete; reinforcing steel; dowels; any other associated materials; and
furnishing all labor, equipment, installation supervision and accessories
required for complete pile installation as shown on the Drawings and
indicated in this Specification Section.
c. Adjustment to bid price for drilled pier length to be made in accordance
with unit prices in the Bid Proposal.
1) Indicate on Bid Proposal Form a single unit price per lineal foot,
for each drilled pier of a given diameter as shown on the
Drawings.
2) These prices will be used to determine any additional amount
due to Contractor if Engineer orders an increase in drilled pier
length, or adjustments due to aborted piers, or credit due to
Owner if decrease in drilled pier length is ordered.
3) No payments for changes in length will be made unless changes
are directed by Engineer and such order is verified in writing.
4) No price adjustment will be made for individual drilled piers but
will be made on the total lineal footage of drilled pier installed
for each diameter.
d. No payment will be made for the following:
1) Drilled piers placed outside of specified tolerances.
2) Drilled piers disapproved by Engineer for reasons stated
elsewhere in this Specification Section.
e. Contractor will be paid for all shafts drilled and terminated and new
foundations placed due to underground obstructions at unit price
indicated in bid documents.
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0537-038-01 DRILLED PIERS JANUARY 2023
1.2 QUALITY ASSURANCE
A. Referenced Standards:
1. American Concrete Institute (ACI):
a. 305R, Hot Weather Concreting.
b. 306R, Cold Weather Concreting.
2. ASTM International (ASTM):
a. A36, Standard Specification for Carbon Structural Steel.
b. A252, Standard Specification for Welded and Seamless Steel Pipe Piles.
B. Qualifications:
1. Installer to have a minimum of five years’ experience in installing drilled piers
in soils similar to those to be encountered on this Project site.
1.3 DEFINITIONS
A. Installer or Applicator:
1. Installer or applicator is the person actually installing or applying the product
in the field at the Project site.
2. Installer and applicator are synonymous.
1.4 SUBMITTALS
A. See Specification Section 01 33 00 for requirements for the mechanics and
administration of the submittal process.
B. Shop Drawings:
1. Fabrication and/or layout drawings.
a. Log of installation of all drilled piers.
b. Shop Drawings of all reinforcing, dowels and accessories required for
the drilled piers.
2. Product technical data including:
a. Acknowledgement that products submitted meet requirements of
standards referenced.
b. Manufacturer's installation instructions.
c. Proposed concrete mix design for drilled piers: See Specification
Section 03 00 05 for information to be included in the mix design
submittal.
3. Certifications.
C. Qualifications:
1. Records for a minimum of three previous installations by the Contractor of
required type of pile and in similar soil conditions.
D. Informational Submittals:
1. Copies of concrete strength tests for concrete placed in the drilled piers.
2. Drilled pier installation log.
PART 2 - PRODUCTS
2.1 CONCRETE
A. Concrete:
1. 28-day minimum compressive strength: 4000 PSI.
2. Comply with Specification Section 03 00 05.
3. Comply with changes as noted in this Specification Section.
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0537-038-01 DRILLED PIERS JANUARY 2023
4. Maximum slump: 6 IN.
5. Portland cement: Type I or II.
6. Concrete admixtures: Comply with Specification Section 03 00 05 when
approved by Engineer.
7. Do not begin installation of drilled piers until the proposed concrete mix
design has been approved by Engineer.
2.2 REINFORCING STEEL
A. Provide reinforcing steel conforming to requirements of Specification Section 03 00
05.
1. Reinforcing sizes, number, configurations, spacing, and lengths to be as
indicated on Drawings.
PART 3 - EXECUTION
3.1 LINES AND LEVELS
A. Furnish lines and levels necessary for drilled pier installation.
1. Contractor is solely responsible for final placement and location of drilled
piers.
3.2 INSTALLATION
A. Provide drilled piers with straight shafts of uniform required diameter as indicated.
B. Drilled pier bottom elevation or elevations indicated on the Drawings are to be used
as a guide and shall be used for bid purposes.
1. Final elevation or elevations of bottom of drilled piers shall be as determined
and directed by Geotechnical Engineer.
C. Provide steel casing in drilled pier holes as required to allow cleaning and inspection
of the bottom of each drilled pier, to prevent caving in and to prevent entering of
ground water into the drilled pier holes.
1. Casing to be steel cylinders of adequate thickness as required to support all
loadings encountered during drilled pier installation.
2. Casing steel to conform to requirements of either ASTM A252, Grade 2, or
ASTM A36.
3. Weld sections of casing together with continuous full penetration welds to
make all joints watertight.
D. Maintain bottom of drilled pier excavations free of loose, wet, soft or frozen
materials, mud, snow and water until drilled pier concrete is placed.
1. Prevent, by whatever means are necessary, the drilled pier bottom
excavations from becoming loose, wet, frozen or soft before drilled pier
concrete is placed.
2. In no case shall there be more than a 1 IN depth of water at bottom of drilled
pier at time of concrete placement.
3. Excavate drilled pier bottoms to a level plane.
E. Remove materials resulting from excavating for drilled piers to an area off-site.
1. Remove excavated materials from around drilled pier holes as soon as
excavation for holes has been completed.
F. Provide gas testing equipment, ventilation equipment, protective cage, and other
safety equipment required for inspection and cleaning of drilled pier excavations or
for any other operations necessitating entry into drilled pier holes.
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0537-038-01 DRILLED PIERS JANUARY 2023
G. Do not begin excavation for any drilled piers until the Geotechnical Engineer is
present to witness the excavation.
1. The bottom subgrade of each drilled pier at time of placing pier concrete shall
be at an elevation which will provide the drilled pier with the following
properties:
a. Free of loose, wet, soft or frozen materials.
b. Free of water exceeding a 1 IN maximum depth.
c. Is at a minimum depth or elevation as indicated in the Drawings.
H. Do not place drilled pier concrete until the Geotechnical Engineer approves the
bottom subgrade of the drilled pier for the above requirements.
I. When drilled pier bottom subgrade does not meet the requirements of this
Specification Section, take corrective action as directed by the Geotechnical
Engineer to bring bottom subgrade into conformance to requirements.
J. After approval of drilled pier bottom subgrade is obtained and after Engineer
approves placement of drilled pier reinforcing steel, dowels and anchor bolts, place
drilled pier concrete as soon as possible, in manner that will preclude segregation of
concrete aggregates, infiltration of water and soil, or any other occurrence which
would tend to decrease strength of concrete or supporting capacity of finished
drilled pier.
1. Limit concrete free fall to 4 FT.
2. Cover open holes for protection of workmen, and to keep out foreign
materials until concrete is placed.
3. Drill and place concrete for a drilled pier in one day's time.
4. Place concrete in a continuous manner to prevent cold joints from forming.
5. Do not allow concrete to free fall through reinforcing steel.
K. When concrete free fall is potentially greater than 4 FT, use tremie method to place
concrete.
1. Use tremie pipe between 6 IN and 8 IN DIA.
2. Provide positive control to ensure that bottom of tremie pipe is at all times
below concrete surface.
L. In withdrawing casing used to brace drilled pier excavation and maintain water
tightness during concrete placement, always keep bottom of casing below top of
concrete surface to prevent a reduction in diameter of drilled pier shaft due to earth
pressure and to prevent soil and ground water from entering and mixing with the
concrete.
1. Pull casing by uniform vertical lifts, continuously plumb, in such a manner to
allow continuous observation of interior level of concrete.
2. Pull casing at a uniform rate.
M. Vibrate top 10 FT of drilled pier concrete.
1. Vibrate each 2 FT lift of this top 10 FT prior to subsequent concrete being
placed.
2. Perform vibration after casing has been withdrawn if casing is not permanent.
N. Surface of drilled pier at cut off elevation to be level with diameter required by
Drawings.
1. Where top surface of drilled pier has a mushroomed configuration, remove
excess concrete in such manner to prevent damage to top of drilled pier and
to provide drilled pier of diameter required.
O. If during drilling, an underground obstruction prevents shaft from being drilled to
required depth, terminate shaft and fill with concrete.
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0537-038-01 DRILLED PIERS JANUARY 2023
1. Notify Engineer so a new drilled pier arrangement and foundation can be
designed to replace terminated shaft.
P. Do not place concrete for drilled piers against soft, loose or frozen ground.
Q. Do not use concrete which has had water added more than 1 HR before placement.
R. After placement of concrete for a drilled pier is completed, cure exposed top surface
of drilled pier for a minimum of seven days.
1. When outside temperature falls below 40 DEGF, maintain temperature of
exposed top surface of drilled piers at a minimum of 50 DEGF during the
curing period.
2. Follow recommendations of ACI 306R for curing concrete in cold weather and
recommendations of ACI 305R for curing concrete in hot weather.
3.3 SUPERVISION AND INSPECTION
A. Drilled pier installer to provide qualified, experienced person in his employ to
supervise all drilling and concrete filling of all drilled piers.
3.4 TOLERANCES
A. Place each drilled pier plumb at locations indicated.
1. Maximum allowable tolerance from true vertical measured from center of
shaft shall not exceed more than 1.5% of the drilled pier length, 12.5% of
shaft diameter, or 15 IN whichever is less.
2. Shaft at cut off elevation shall not be off center horizontally from its required
location more than 1/24 of shaft diameter or 2 IN, whichever is less.
3. If tolerances are exceeded, Contractor to pay for corrective design and
construction that may be required.
3.5 REINFORCEMENT
A. Place steel reinforcing cage in drilled pier holes as indicated after Geotechnical
Engineer has approved drilled pier bottom subgrade and before placing concrete.
1. Adequately support reinforcement by means to ensure indicated vertical
position, concentric alignment and required concrete cover over reinforcing
steel.
2. Provide additional reinforcing steel in drilled piers as directed by Engineer due
to revised condition of drilled pier installation.
3. Place all dowels extending from tops of drilled piers immediately after
concrete shaft has been fully placed.
3.6 DISAPPROVED DRILLED PIERS
A. Drilled piers will be disapproved and replaced as directed by Engineer for following
reasons:
1. Concrete not reaching minimum required 28-day compressive strength, or
containing cracks, voids, soft material, inclusions of earth or other foreign
materials, or any other defect which, in the opinion of the Engineer, may
affect the strength of the drilled pier.
2. Drilled piers out of horizontal and vertical alignment in excess of tolerances
specified.
3. Drilled piers of improper size and depth, and drilled piers suspected to be of
incorrect diameter due to any reason.
B. Any additional drilled piers or additional construction required due to disapproved
drilled piers will be placed by Contractor at no additional expense to Owner.
PLUMMER ASSOCIATES, INC. 31 63 29 - Page 5 of 6 BID SET
0537-038-01 DRILLED PIERS JANUARY 2023
C. Reimburse Engineer for any additional engineering work required for redesign due to
disapproved drilled piers.
3.7 FIELD QUALITY CONTROL
A. Owner pays for inspection and testing:
1. Owner will employ and pay for services of an independent testing/inspection
agency to inspect drilled piers and provide the services indicated in this
Section as being performed by the Geotechnical Engineer.
B. Contractor provides sufficient notification and access so inspection and testing can
be accomplished.
C. Contractor pays for retesting of failed tests and for additional testing required when
defects are discovered.
D. Responsibilities of Testing Agency and/or Special Inspector:
1. Inspect piles which have been installed for general conformance with this
Specification Section.
2. Prepare and submit inspection and test reports to Engineer.
a. Coordinate such work with other Special Inspectors.
b. Assist Engineer to determine corrective measures necessary for
defective work.
E. Make three (3) 6 IN DIA x 12 IN high concrete test cylinders for each 20 CY of
concrete or fraction thereof placed.
1. Indicate which drilled piers the test cylinders represent.
2. Make cylinders and test in compliance with Specification Section 03 00 05.
3. Along with each set of three cylinders, make one test each for slump, air
content and concrete temperature.
4. Test one cylinder at seven days and two cylinders at 28 days.
5. Furnish a copy of all test results to Engineer.
3.8 DRILLED PIER RECORDS
A. Keep a log of each installed drilled pier including:
1. Drilled pier location by column grid lines or by other means.
2. Date drill pier was installed.
3. Bottom elevation of drilled pier.
4. Cut off elevation of drilled pier.
5. Total length of drilled pier from bottom to cut off elevation.
6. Diameter of drilled pier shaft.
7. Whether or not hole was cased.
8. Deviation from allowable installation tolerances.
9. Stratigraphy of subgrade materials encountered during drilling.
10. Concrete delivery ticket truck numbers used to fill drilled pier.
B. After all drilled piers are installed, submit copy of complete drilled pier logs to
Engineer.
1. Report to be signed by Contractor and Testing Agency/Special Inspector.
END OF SECTION
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0537-038-01 DRILLED PIERS JANUARY 2023
SECTION32 11 34
CEMENT STABILIZED SAND
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section provides the requirements for materials used for backfill that required stabilized
material where specifically called out in the drawings.
Related Sections:
Section 31 20 00 “Earthwork” for structural backfill.
1.3SUBMITTALS
Contractor Design Mix Determination: Submit proposed mix design for and preliminary
results demonstrating the mix design achieves required compressive strength.
Source of Materials: Submit name and location of source of materials.
1.4REFERENCES
ASTM International (ASTM):
C117 –Standard Test Method for Material Finer than 75 Micrometer (No. 200) Sieve
in Mineral Aggregates by Washing.
C136 –Standard Test Method for Sieve Analysis of Fine and coarse Aggregates.
C150 –Standard Specification for Portland Cement.
D4318 –Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of
Soils.
D558 –Standard Test Methods for Moisture-Density (Unit Weight) Relations of Soil-
Cement Mixtures
1.5DELIVERY, STORAGE AND HANDLING
Store and handle materials in a manner to prevent contamination.
PRODUCTS
2.1CEMENT
Type I Portland Cement conforming to ASTM C150 shall be used.
2.2SAND
Sand shall be free from organic or otherwise deleterious materials and shall confirm to the
following requirements:
Sieve SizePercent Passing (%)
100
3/8-inch
0-20
#200
The Plasticity Index (P.I.) shall not exceed six (6).
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2.3WATER
Water: Water shall be reasonably clean, free from injurious amounts of oil, acid, salt,
organic matter, or other deleterious materials.
2.4DESIGN REQUIREMENTS
The cement stabilized sand shall have a comprehensive strength of 50 to 150 psi in 28 days.
EXECUTION
3.1MIXING
The cement, aggregate, and water shall be thoroughly mixed in an approved processing
plant. The moisture content ofthe mixture shall be maintained between onepercent below
and two percentage points above optimum moisture. The amounts of cement are expressed
as percentage of dry weights.
3.2PLACEMENT
Placement of cement stabilized sand shall be in 8-inch-thick lifts and to be compact to 95%
of ASTM D558 unless other specified by the engineer. Compaction shall continue until the
entire depth of the mixture is uniformly compacted.
Compaction shall be within four (4) hours of the addition of water to the dry mixed material.
Cement stabilized sand shall not be placedor compacted in standing or free water.
Any material left in stockpile after four (4) hours should be discarded.
END OF SECTION
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SECTION 32 12 73
PAVEMENT JOINT SEALANTS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARYS
This Section specifies the pavement joint sealants used for sealing expansion and
contraction joints within cement concrete pavement; joints between concrete pavement and
adjacent work; and joints between cement concrete and asphalt pavement.
1.3SUBMITTALS
Product Data: For each type of product indicated.
Product certificates.
1.4REFERENCES
ASTM International (ASTM):
C920 –Specification for Elastomeric Sealants
C1193 –Guide for Use of Joint Sealants
D3405 –Specification for Joint Sealants, Hot-Applied, for Concrete and Asphalt
Pavements
D3406 –Specification for Joint Sealant, Hot-Applied, Elastomeric-Type, for Portland
Cement Concrete Pavements
D3569 –Specification for Joint Sealant, Hot-Applied, Elastomeric, Jet-Fuel-Resistance-
Type for Portland Cement Concrete Pavement
D3581 –Specification for Joint Sealant, Hot-Poured, Jet-Fuel-Resistance-Type, for
Portland Cement Concrete and Tar-Concrete Pavements
D5249 –Specification for Backer Materials for Use with Cold-and Hot-Applied Joint
Sealants in Portland Cement concrete and Asphalt Joints
D5893 –Specification for Cold applied, Single Component, Chemically Curing silicone
joint Sealant for Portland Cement Concrete Pavements
PRODUCTS
2.1MANUFACTURERS
Available Products: Subject to compliance with requirements, products that may be
incorporated into the Work include, but are not limited to, products listed in other Part2
articles.
2.2MATERIALS, GENERAL
Compatibility: Provide joint sealants, backing materials, and other related materials that are
compatible with one another and with joint substrates under conditions of service and
application, as demonstrated by joint-sealant manufacturer based on testing and field
experience.
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Primers: Product recommended by joint-sealant manufacturer where required for
adhesion of sealant to joint substrates indicated, as determined from preconstruction
joint-sealant-substrate tests and field tests.
Colors of Exposed Joint Sealants: As selected by ENGINEER from manufacturer's full range.
2.3COLD-APPLIED JOINT SEALANTS
Multi-component Jet-Fuel-Resistant Sealant for Concrete: Pourable, chemically curing
elastomeric formulation complying with the following requirements for formulation and with
ASTMC920 for type, grade, class, and uses indicated:
Urethane Formulation: TypeM; GradeP; Class12-1/2; UsesT, M, and, as applicable
to joint substrates indicated, O.
Available Product:
Pecora Corporation; UrexpanNR-300.
Coal-Tar-Modified Polymer Formulation: TypeM; GradeP; Class25; UsesT and, as
applicable to joint substrates indicated, O.
AvailableProduct:
Meadows, W. R., Inc.; Sealtight Gardox.
Bitumen-Modified Urethane Formulation: TypeM; GradeP; Class25; UsesT, M, and,
as applicable to joint substrates indicated, O.
AvailableProduct:
Tremco Sealant/Waterproofing Division; Vulkem202.
Single-Component Jet-Fuel-Resistant Urethane Sealant for Concrete: Single-component,
pourable, coal-tar-modified, urethane formulation complying with ASTMC920 for TypeS;
GradeP; Class25; UsesT, M, and, as applicable to joint substrates indicated, O.
AvailableProducts:
Sonneborn, Div. of ChemRex, Inc.; Sonomeric1.
TypeNS Silicone Sealant for Concrete: Single-component, low-modulus, neutral-curing,
non-sag silicone sealant complying with ASTMD5893 for TypeNS.
AvailableProducts:
Crafco Inc.; RoadSaver Silicone.
Dow Corning Corporation; 888.
TypeSL Silicone Sealant for Concrete and Asphalt: Single-component, low-modulus, neutral
curing, self-leveling silicone sealant complying with ASTMD5893 for TypeSL.
AvailableProducts:
Crafco Inc.; RoadSaver SiliconeSL.
Dow Corning Corporation; 890-SL.
Multi-component Low-Modulus Sealant for Concrete and Asphalt: Proprietary formulation
consisting of reactive petropolymer and activator components producing a pourable, self-
leveling sealant.
AvailableProducts:
Meadows, W. R., Inc.; Sof-Seal.
2.4HOT-APPLIED JOINT SEALANTS
Jet-Fuel-Resistant Elastomeric Sealant for Concrete: Single-component formulation
complying with ASTMD3569.
AvailableProducts:
Crafco Inc.; Superseal444/777.
Meadows, W. R., Inc.; Poly-Jet3569.
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Jet-Fuel-Resistant Sealant for Concrete and Tar Concrete: Single-component formulation
complying with ASTMD3581.
AvailableProducts:
Crafco Inc.; Superseal1614A.
Meadows, W. R., Inc.; Poly-Jet1614.
Meadows, W. R., Inc.; Poly-Jet3406.
Meadows, W. R., Inc.; Poly-Jet3569.
Elastomeric Sealant for Concrete: Single-component formulation complying with
ASTMD3406.
AvailableProducts:
Crafco Inc.; Superseal444/777.
Meadows, W. R., Inc.; Poly-Jet3406.
Sealant for Concrete and Asphalt: Single-component formulation complying with
ASTMD3405.
AvailableProducts:
Koch Materials Company; Product No.9005.
Koch Materials Company; Product No.9030.
Meadows, W. R., Inc.; Sealtight Hi-Spec.
2.5JOINT-SEALANT BACKER MATERIALS
General: Provide joint-sealant backer materials that are non-staining; are compatible with
joint substrates, sealants, primers, and other joint fillers; and are approved for applications
indicated by joint-sealant manufacturer based on field experience and laboratory testing.
Round Backer Rods for Cold-and Hot-Applied Sealants: ASTMD5249, Type1, of diameter
and density required to control sealant depth and prevent bottom-side adhesion of sealant.
Backer Strips for Cold-and Hot-Applied Sealants: ASTMD5249; Type2; of thickness and
width required to control sealant depth, prevent bottom-side adhesion of sealant, and fill
remainder of joint opening under sealant.
Round Backer Rods for Cold-Applied Sealants: ASTMD5249, Type3, of diameter and
density required to control sealant depth and prevent bottom-side adhesion of sealant.
EXECUTION
3.1INSTALLATION
Surface Cleaning of Joints: Clean out joints immediately before installing joint sealants to
comply with joint-sealant manufacturer's written instructions.
Joint Priming: Prime joint substrates where indicated or where recommended in writing by
joint-sealant manufacturer, based on preconstruction joint-sealant-substrate tests or prior
experience.
Sealant Installation Standard: Comply with recommendations in ASTMC1193 for use of
joint sealants as applicable to materials, applications, and conditions indicated.
Install backer materials to support sealants during application and at position required to
produce optimum sealant movement capability. Do not leave gaps between ends of backer
materials. Do not stretch, twist, puncture, or tear backer materials. Remove absorbent
backer materials that have become wet before sealant application and replace them with dry
materials.
Install sealants at the same time backings are installed to completely fill recesses provided
for each joint configuration and to produce uniform, cross-sectional shapes and depths
relative to joint widths that allow optimum sealant movement capability.
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Tooling of Nonsag Sealants: Immediately after sealant application and before skinning or
curing begins, tool sealants to form smooth, uniform beads of configuration indicated; to
eliminate air pockets; and to ensure contact and adhesion of sealant with sides of joint.
Clean off excess sealants or sealant smears adjacent to joints as the Work progresses by
methods and with cleaning materials approved by manufacturers of joint sealants and of
products in which joints occur.
END OF SECTION
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SECTION 33 0561
MANHOLES
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section specifies manholes for storm sewer systems, sanitary sewer systems, and other
utilities as required and shown on the Drawings. This Section includes the following:
Precast reinforced concrete manholes.
Cast-in-place reinforced concrete manholes.
Fiberglassmanholes.
Related Sections:
Section 33 71 19“Electrical Underground Ducts, Ductbanks, and Manholes” for
requirements for manholes, structures, and related work for electrical and utility
systems.
1.3REFERENCES
American Association of State Highway and Transportation Officials (AASHTO):
M 306 –Specification for Drainage Structure Castings
ASTM International (ASTM):
C 76 –Specification for Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe
C 443 –Specification for Concrete Pipe and Manholes, Using Rubber Gaskets
C 478 –Specification for Precast Concrete Manhole Sections
C 890 –Practice for Minimum Structural Design Loading for Monolithic or Sectional
Precast Concrete Water and Wastewater Structures
C 915 –Specification for Precast Concrete Water and Wastewater Structures
C 923 –Specification for Resilient Connectors Between Reinforced Concrete Manhole
Structures, Pipes, and Laterals
C 990 –Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections
Using Preformed Flexible Joint Sealants
D3753 –Specification for Glass-Fiber-Reinforced Polyester Manholes and Wetwells
1.4SUBMITTALS
Product Data:
Provide design of joint or joints, including design and durometer hardness of the
rubber gasket proposed.
Product data for precast riser sections, covers, frames, grade rings, and pipe sleeves.
Shop Drawings: For manholes: Include plans, elevations, sections, details, and
attachments to other work.
Documentation:
For castings furnish manufacturer’s certification stating the casting meets the proof-
load testing requirements of AASHTO M 306.
Field Quality Control Reports: Provide field testing reports.
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1.5DELIVERY, STORAGE, AND HANDLING
Joint Materials. Store gaskets and sealants in as cool, clean, and shaded place as
practicable, preferably at 70°F or less. Storelubricant in accordance with manufacturer’s
recommended temperature range.
PRODUCTS
2.1PRECAST CONCRETE MANHOLES
Standard Precast Concrete Manholes: ASTMC478, precast, reinforced concrete, of depth
indicated, with provision for sealant joints.
Designed Precast Concrete Manholes: ASTMC913; designed according to
ASTMC890 for A-16 (AASHTOHS20-44), heavy-traffic, structural loading; of depth,
shape, and dimensions indicated, with provision for sealant joints.
Cement: ASTMC150, TypeII.
Diameter: 48 inches minimum for pipe sizes up to and including 15-inches, unless
otherwise indicated. For pipe sizes greater than 30-inches, manhole diameter shall be
as shown on the Drawings.
Base Section: 5-inch minimum thicknessfor manholes 48-inch diameter, 6-inch
minimum thickness for manholes 60-inch diameter, 8-inches for larger diameter
manholes, or as shown on the Drawings.
Riser Sections: Minimum wall thickness shall be as listed under Wall “B” in the “Class
Tables” of ASTM C 76, and lengths to provide depth indicated.
Top Section: Eccentric-cone type unless concentric-cone or flat-slab-top type is
indicated. Top of cone of size that matches grade rings.
Joint Sealant: ASTMC990, bitumen or butyl rubber.
Resilient Pipe Connectors: In accordance with ASTMC923, cast or fitted into
manhole walls, for each pipe connection. The resilient connector shall provide an
airtight seal that eliminates infiltration and exfiltration.
Steps: Unless otherwise noted, manhole steps shall not be provided. If required,
provide individual FRP steps, FRP ladder, or rubber coated steel type; wide enough to
allow worker to place both feet on one step; and designed to prevent lateral slippage
off of step and capable of supportinga concentrated load of 300 pounds. Cast or
anchor steps into sidewalls at 12-to 16-inch intervals. Omit steps if total depth from
floor of manhole to finished grade is less than 60 inches.
Joints: Conform to the joint specification of ASTM C 478, use rubber gaskets ofthe
round O-ring design complying with requirements of ASTM C 443.
Adjusting Rings: Interlocking rings with level or sloped edge in thickness and diameter
matching manhole frame and cover. Include sealant recommended by ring
manufacturer.
Grade Rings: Reinforced concrete rings, maximum 18-inch total thickness, to match
diameter of manhole frame and cover.
Lifting Lugs: Manhole sections and cones may be furnished with lift lugs or lift holes.
If lift holes are provided, they shall be plugged with a nonmetallic, non-shrink grout.
Apply a bituminous water proofing coating to the exterior surfaces of the precast
manhole sections.
When designated on the Drawings, apply a corrosion resistantmaterial to the interior
surfaces of the manhole.
A corrosion resistant material meeting the requirements of Section 40 46 16
“Protective Liquid Linings and Coatings for Substrates Exposed to a Corrosive
Wastewater Environment” shall be applied to the manhole from 1 foot above the
entry point for any line containing a condensate drain down to the manhole invert.
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2.2CAST-IN-PLACE CONCRETE MANHOLES
Construct of reinforced-concrete bottom, walls, and top; designed according to ASTMC890
for A-16 (AASHTOHS20-44), heavy-traffic, structural loading; of depth, shape, dimensions,
and appurtenances indicated.
Diameter: 48 inches minimum for pipe sizes up to and including 15-inches, unless
otherwise indicated. For pipe sizes greater than 30-inches, manhole diameter shall be
as shown on the Drawings.
Base Section: 5-inch minimum thickness for manholes 48-inch diameter, 6-inch
minimum thickness for manholes 60-inch diameter, 8-inches for larger diameter
manholes, or as shown on the Drawings.
Ballast: Increase thickness of concrete, as required to prevent flotation.
Resilient Pipe Connectors: In accordance with ASTMC923, cast or fitted into
manhole walls, for each pipe connection. The resilient connector shall provide an
airtight seal that eliminates infiltration and exfiltration.
Steps: Unless otherwise noted, manhole steps shall not be provided. If required,
provide individual FRP steps, FRP ladder, or rubber coated steel type; wide enough to
allow worker to place both feet on one step; and designed to prevent lateral slippage
off of step and capable of supporting a concentrated load of 300 pounds. . Cast or
anchor steps into sidewalls at 12-to 16-inch intervals. Omit steps if total depth from
floor of manhole to finished grade is less than 60 inches.
Adjusting Rings: Interlocking rings with level or sloped edge in thickness and diameter
matching manhole frame and cover. Include sealant recommended by ring
manufacturer.
Grade Rings: Reinforced concrete rings, maximum 18-inch total thickness, to match
diameter of manhole frame and cover.
Apply a bituminous water proofing coating to the exterior surfaces of the precast
manhole sections.
When designated on the Drawings, apply a corrosion resistantmaterial to the interior
surfaces of the manhole.
A corrosion resistant material meeting the requirements of Section 40 46 16
“Protective Liquid Linings and Coatings for Substrates Exposed to a Corrosive
Wastewater Environment”shall be applied to the manhole from 1 foot above the
entry point for any line containing a condensate drain down to the manhole invert.
2.3MANHOLE FRAMES AND COVERS
Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
John Bouchard & Sons Company
Neenah Foundry Company
Vulcan Foundry.
Construction: Ferrous; 30-inch ID by 7-to 9-inch riser with 4-inch-minimum width flange
and 32-inch diameter cover, or of the size and type as shown on the Drawings.
Include indented top design with lettering cast into cover identifyingservice, with
wording equivalent to "STORM SEWER”, “SANITARY SEWER”, “VALVE”, or as
indicated on the Drawings.
When specified on Drawings, or required by the governmental agency having
jurisdiction, provide type of cover and cover identity in accordance with applicable
requirements.
Material: ASTMA48, Class35B gray iron, or ASTM A 536, Grade 65-45-12 ductile
iron, unless otherwise indicated.
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Frame, ring, and cover shall meet proof-load testing requirements of ASSHTO M
306.
Protective Coating: Foundry-applied, SSPC-Paint16, coal-tar, epoxy-polyamide paint;
10-mil minimum thickness applied to all surfaces, unless otherwise indicated.
Watertight Construction: Conform to above but furnished with a neoprene O-ring gasket and
countersunk stainless-steelbolts to form a watertight seal between the cover sealing surface
and the frame.
Manhole Cover Inserts: Manufactured, plastic form, of size to fit between manhole frame
and cover and designed to prevent storm water inflow. Include handle for removal and
gasket for gastight sealing. Covers shall be bolted and gasketed when shown on the
Drawings and where installed below the 100-year floodplain.
2.4CONCRETE
General: Cast-in-place concrete according to ACI318/318R, ACI350R, and the following:
Cement: ASTMC150, TypeII, IIA, or I-II.
Fine Aggregate: ASTMC33, sand.
Coarse Aggregate: ASTMC33, crushed gravel.
Water: Potable.
Portland Cement Design Mix: 4000-psi minimum, with 0.45 maximum water-cementitious
materials ratio.
Reinforcement Fabric: ASTMA185, steel, welded wire fabric, plain.
Reinforcement Bars: ASTMA615/A615M, Grade60, deformed steel.
Ballast and Pipe Supports: Portland cement design mix, 3000-psi minimum, with 0.58
maximum water-cementitious materials ratio.
Reinforcement Fabric: ASTMA185, steel, welded wire fabric, plain.
Reinforcement Bars: ASTMA615/A615M, Grade60, deformed steel.MORTAR
Mortar: Furnish mortar comprised of one part Portland cement, ASTM C 150, Type II, IIA, or
I-II, and two parts clean sand.
2.5FACTORY FABRICATED FIBERGLASS (FRP) MANHOLES
Provide Prefabricated Fiberglass Manholes conforming in shape, size, dimensions and details
shown in the Drawings, or as follows:
Dimensions: The large diameter manholes shall be a circular cylinder, sized per the
plans for the applicable stations. Large diameter manholes shall be produced in per
the length in the plant ±½-inch. Nominal inside diameters shall be 60-inch, 66-inch,
72-inch, 96-inch, 120-inch, 132-inch, 168-inch, 186-inch, 192-inch, 216-inch, and
240-inch, or as shown on the Plans. Tolerance on the inside diameter shall be
±1percent.
The manufacturer of the large diameter manhole shall be able to show experience in
the manufacture of FRP large diameter manholes for more than five years.
Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the work include the following:
Containment Solution, Inc.
Associated Fiberglass Enterprises.
Unless modified in the Drawings, use manhole sections conforming to ASTM D3753.
Mark date of manufacture and name or trademark of manufacturer in 1-inch tall stenciled
letters on the inside of the barrel.
Manufacturer’sidentification
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Manufacturer’s serial number
Large diameter manhole diameter and length
ASTM designation
For 5-foot diameter manhole, shall be fabricated and delivered with a vertical riser and
conical top in one piece with 12-inch long integral stubouts for joining the sewer pipes.
For 5-foot diameter manholes, risers shall be 60-inch inside diameter with a top cone section
fabricated to mount the frame and cover as shown in the plans.
Manhole lifting lugs shall be provided.
All hardware, fasteners, and anchors shall be Type 316 stainless steel.
FRP manhole interior and exterior surfaces shall be resin rich and have chemical resistant
polyester resin and grade E glass reinforcing content of 30 percent by weight with 20 mils
minimum thickness.
For 5-foot diameter manholes, minimum wall thickness shall be ½-inch. For large diameter
manholes, minimum wall thickness shall be per ASTM 3753 and H20 load bearing.
End couplings, sleeves, and Type 316 stainless steel clamps or push-on rubber gasket joints
to connect piping to manhole stubouts. Sleeves shall be as manufactured by GPK Products,
Inc., of Fargo, North Dakota, or approved equivalent.
Resilient Pipe Connectors: In accordance with ASTMC923, cast or fitted into manhole walls,
for each pipe connection. The resilient connector shall provide an airtight seal that
eliminates infiltration and exfiltration.
All manholes shall have a minimum diameter of five feet unless a larger diameter is noted in
the plans or required by the piping configuration shown. Provide larger diameter manholes
where necessary to maintain at least a 12-inch clearance between any holes cut in the riser
section.
Large diameter manholes, lengths shall be per requirements ±½-inch. For large diameter
manholes, risers shall be 30-inch or 24-inch as shown on the plans with the riser fabricated
monolithically with the FRP manhole top.
Stiffness: The cylindrical portion of the large diameter manhole is to be tested in accordance
with ASTM Method D2412. The large diameter manhole cylinder shall have the minimum
pipe-stiffness values shown in the table below, when tested in accordance with ASTM 3753,
Section8.5 (note 1).
Large diameter manhole Length PSI
(ft)
3 -60.72
7 -121.26
3 -202.01
21 -253.02
26 -355.24
Chemical Resistance: Per ASTM C581 (see ASTM 3753, Section 8.7), flexural strength,
flexural modulus, and barcol hardness are plotted versus time on log-log coordinates. The
line defined by these points is extrapolated to 100,000 hours. The minimum extrapolation
retention allowed for any of these properties is 50percent. Test samples used are actual
pieces of large diameter manhole or samples manufactured in a manner consistent in every
way with the large diameter manhole component construction.
Physical Properties:
3
Flexural Strength (pipe)Hoop:22.5 x 10psi
3
Axial:14.3 x 10psi
3
Compressive Strength:8.9 x 10psi
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EXECUTION
3.1GENERAL
Manhole Types and Requirements:
Manholes shall be concrete except as noted otherwise on drawings. Where manholes
are used on CCFRP pipes a fiberglass manhole shall be used.
Manholes in water lines shall be precast or cast-in-place reinforced concrete
construction in accordance with the Drawing requirements.
Manholes for storm sewer service shall be precast or cast-in-place reinforced concrete
construction in accordance with the Drawing requirements.
Earthwork: Excavation, trenching, and backfilling are specified in Section 31 23 00
“Excavation, Trenching, and Backfilling for Utilities.”
3.2MANHOLE INSTALLATION
Manhole Base: Construct either cast-on-site or monolithic round, precast reinforced concrete
base section. The base shall have a minimum thickness indicated above and projects no less
than 6-inches beyond the outside walls of the base to form a flange intended to resist uplift.
The precast concrete base shall have suitable cutouts or openings to receive all pipes
and connections. The lowest edge of openings shall be no less than 6-inches above
the inside surface of the floor of the base.
Precast Manholes:
Construct precast manholes of the sizes and configuration at the locations in
accordance with ASTM C 478 and as indicated on the Drawings.
Provide required pipe connections and invert channels as shown on the Drawings and
described in this Section.
When indicated on the Drawings, provide bituminous water proofing to exterior
surfaces and/or corrosion resistance coating on interior surfaces.
Test completed manhole.
Cast-In-Place Manholes:
Construct cast-in-place manholes of the sizes and configuration at the locations in as
indicated on the Drawings.
Provide required pipe connections and invert channels as shown on the Drawings and
described in this Section.
When indicated on the Drawings, provide bituminous water proofing to exterior
surfaces and/or corrosion resistance coating on interior surfaces.
Test completed manhole.
Invert channels construction:
Invert channels shall be smooth, accurately shaped, and in accordance with the
Drawings.
Invert may be formed directly in the concrete of the manhole base, shaped by
mortar, or constructed by laying a section of pipe through the manhole and cutting
the top half after the concrete base is constructed and set.
Changes in directions and grade will consist of the largest curve radius the manhole
diameter will permit.
Free vertical drop from any branch or service line shall not exceed one half the
mainline pipe diameter measured from the mainline upstream invert.
The top of themanhole base outside the flow channels shall be steeply sloped to the
channels.
Piping Connections:
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Where piping is connected to a manhole, provide resilient connector in accordance
with ASTM C 923.
Manufacturers:Subject to compliance with requirements,available manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Press Seal Gasket Corporation, Fort Wayne, Indiana;
PSX Manhole Connector.
Hamilton Kent
Universal Polymer
When manhole base is concrete and cast around the pipe,install an adapter gasket to
serve as a watertight seal (water stop) between pipe and concrete.
When resilient connectors cannot be made for manhole connections, ensure the pipe
does not extend any further than five feet from outside manhole wall or base. Provide
a concrete cradle within one foot of the pipe end. Extend the concrete manhole base
to support the cradle. Provide manufacturer’s recommended adapter shall be used to
connect the pipe to themanhole pipe.
Where the main line (lowest line) passes straight through manhole, or the degree of
deflection is less than 5 degrees, and no other line invert enters below the centerline
of the main line, lay the main line continuous through manhole.
When the degree of deflection is greater than 5 degrees, or the invert of another line
enters at or below the centerline, terminate the main line laying such that the pipe
ends are flushed with the inside manhole wall.
Field Connections to Manholes:
Cut neat opening in manhole no larger than necessary to insert pipe.
Utilize PVC sleeves with rubber gaskets and abrasive silica outer coating. After
installing new lines, place concrete collar around pipe on outside of manhole to seal
joint. Make collar approximately 8inches wide by 8 inches deep.
Use concrete having minimum compressive strength of 3000-psi at 28-days.
Modify invert channel in manhole to provide smooth transition into or out of new pipe.
3.3MANHOLE FRAMES AND COVERS
Provide manhole frame and cover atthe location of the type as indicated on the Drawings.
Frame opening shall be 30-inch minimum nominal size.
Set tops of frames and covers flush with finished surface of manholes that occur in
pavements. Set tops 3 inches above finished surface elsewhere,unless otherwise indicated.
Not less than two precast concrete grade rings, with a maximum total thickness of 18-
inches, shall be placed under the frame. Use no more than four grade rings per manhole.
Ring hold down bolts(4 minimum)shall pass through the grade rings into the top of the
cone.
3.4FIELD QUALITY CONTROL
Testing Agency: Engage a qualified testing agency to perform tests and inspections.
Perform tests and inspections.
Tests and Inspections: Manholes shall be tested by hydrostatic exfiltration or vacuum testing
either according to requirements of authorities having jurisdiction or as specified on the
Drawings by one of the methods described below. Manholes shall be tested after installation
with all connections (existing and/or proposed) in place.
Water Exfiltration Test:
Test sanitary and storm sewer manholes independently of lines by sealing
connecting lines using a plug. Fill manhole to bottom of frame with water.
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For concrete manholes allow a stabilization period of twelve hours prior to
testingfor absorption of water by the concrete. After which refill with water as
necessary.
The test period shall be two (2) hours, after which the manhole shall be
refilled, measuring the quantity of water.
The allowable leakage of water shall be 0.025 gallons per foot diameter per
vertical foot per day, and is represented by the following formula:
V =0.025 DHT/24
Where:V = Allowable loss in gallons
D = Manhole diameter in feet
H = Initial depth of water to invert in feet
T = Duration of test in hours.
At treatment plants all manholes shall be tested. For conveyance systems away from
a treatment plant sanitary and storm sewer manholes shall be tested at random;
however, not less than 20% of the total number of manholes identified on the Project
shall betested.
Vacuum Testing Manholes:
When specified on the Drawings, vacuum test manholes.
Test manholes prior to installation of the ring and cover and grade adjustment
rings are installed, and after backfill and compaction are completed.
Conduct tests in accordance with ASTM C 1244 and this Section.
Preparation for tests:
All lift holes, joints, and other imperfections shall be filled with a non-metallic,
non-shrink grout, providing a smooth finish appearance.
All pipes entering manhole shall be plugged, taking care to brace the pipes and
plugs to prevent them from being drawn into the manhole.
Test Procedure:
Placed test head on manhole in accordance with manufacturer’s
recommendation.
A vacuum of 10-inches Mercury shall be drawn in the manhole, the valve on
the vacuum line closed, and the vacuum pump shut off.
Measure the time for the vacuum to drop to 9-inches Mercury.
The manhole shall pass if the time for the vacuum reading to drop from 10-
inches Mercury to 9-inches Mercury meets or exceeds the values indicated in
Table 1.
Table 1-Minimum Vacuum Test Times for Various Manhole Diameters
Manhole Diameter (inches)
Depth of MH
(Feet)486072
Minimum Time Required
For a Vacuum Drop of 1” Mercury
(minutes: seconds)
0 -200:400:501:00
220:440:551:06
240:481:001:12
260:521:051:18
280:561:101:24
301:001:151:30
See Note 10:040:050:06
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1. Additional 2-ft. depths, add additional time for each 2-ft.
If manhole fails test, necessary repairs shall be made by using a non-shrink grout or
other suitable material based on material from which the manhole was constructed,
and manhole retested until a satisfactorily test is obtained.
Manhole will be considered defective if it does not pass tests and inspections.
Prepare test and inspection reports.
3.5ADJUSTING AND CLEANING
Either adjusts manhole cover and frame or roadway surface to obtain a smooth transition if
manhole located in roadway. Adjust surrounding grade, filling any depressions, around
manhole.
Removal construction debris, trash, and plugs from manhole prior to placing in service.
END OF SECTION
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SECTION 33 14 19
DRAINS, CLEANOUTS, HYDRANTS, AND HOSE STATIONS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section provides requirements for drains, hydrants, and cleanouts for interior and exterior
applications and includes:
1. Floor drains.
2. Hub drains.
3. Trench drains.
4. Cleanouts.
5. Fire Hydrants
6. Yard Hydrants and Hose Stations.
B. Related Sections:
1. Refer to Section 40 05 05 “Piping System, Basic Materials and Methods” for information
regarding submittals; coordination; material delivery, handling, and storage; projection
conditions; design requirements; other materials; installation of piping systems; field
testing; and related work.
1.3 SUBMITTALS
A. Information Submittal: Provide manufacturer’s data sheet and warranty information for each
type of product indicated.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, those named
in the following paragraphs.
2.2 FLOOR DRAINS
A. Floor Drain, Round Top, FD-1: Corresponds to drains that are directly connected to 10-inch
and 12-inch pipe. Furnish duracoated cast iron floor drain, medium duty application, with
bottom outlet, seepage pan and combination membrane flashing clamp and frame,
approximately 21-inch round double slotted grate similar to Zurn Series Z547. Drain outlet
shall be same size as drain piping shown on Drawings.
B. Floor Drain, Round Top, FD-2: Corresponds to drains that are directly connected to 6-inch
and 8-inch pipe. Furnish duracoated cast iron floor drain, medium duty application, with
bottom outlet, seepage pan and combination membrane flashing clamp and frame,
approximately 12-inch round double slotted grate similar to Josam Series 32300 and Zurn
Series Z500. Drain outlet shall be same size as drain piping shown on Drawings.
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C. Floor Drain, Round top, FD-3: Corresponds to drains that are directly connected to 4-inch and
smaller pipe. Furnish duracoated cast iron floor drain, medium duty application, with bottom
outlet, seepage pan and combination membrane flashing clamp and frame, approximately 8-
inch round double slotted grate similar to Josam Series 32100 and Zurn Series Z500. Drain
outlet shall be same size as drain piping shown on Drawings.”
D. Floor Drain, Rectangular Top, FD-4: Furnish rectangular adjustable strainer top with
duracoated cast iron head, polished nickel bronze frame and secured slotted grate. Size shall
be 5” x 17” or as indicated on the Drawings. Rectangular floor drain shall be similar to Zurn
Type “J” rectangular strainer with slotted opening.
E. Floor Drain, Square Top, FD-5: Furnish coated cast iron floor drain with 14-inch square grate
set in square frame, grate support collar with double drainage flange and weep-holes,
bottom outlet, adjustable collar, support ring, large sump body, removable sediment bucket
and heavy duty iron grate similar to Josam Series 37900.
F. Hub Drain, FD-5: Furnish duracoated cast hub drain adapter with standard cast iron soil pipe
hub and female threaded outlet, similar to Josam Series 88550. Pipe size shall be same size
as drain piping shown on Drawings.
2.3 TRENCH DRAIN SYSTEM
A. Trench Drain System, TD-1:
1. Provide modular channel sections, 80” long, 17” wide, and a 12” wide throat
constructed of HDPE, with interlocking ends and radius bottom.
2. Channels shall be provide with 1.0% built-in slope and inverts ranging from 9.25” to
34.21”.
3. Channels shall have clips for anchoring to vertical re-bar and a heavy duty steel frame
for securing the grate.
4. Provide a ductile iron grate design for H-20 loadings with mechanical lock down
devices.
5. Provide bottom outlet in 8”diameter.
6. Trench drain similar to Zurn Flo-Thru Model 874-12.
B. Trench Drain System, TD-2:
1. Provide modular channel sections, 40” long, 6” wide, and a 4” wide throat constructed
of HDPE, with interlocking ends and radius bottom.
2. Channels shall be provided with flat bottom and a 3-1/2” invert.
3. Channels shall have clips for anchoring to vertical re-bar and a heavy duty steel frame
for securing the grate.
4. Provide a ductile iron grate design for H-20 loadings with mechanical lock down
devices.
5. Provide end outlet in 2” diameter and bottom outlets in 4” diameter.
6. Trench drain similar to Zurn Flo-Thru Model 883.
2.4 CLEANOUTS
A. Finished Floors and Concrete Floors, CO-1: Provide duracoated cast-iron, adjustable cleanout
with gas and watertight ABS tapered thread plug, and scoriated secured cover and frame,
similar to Zurn Model Z1402. Pipe size shall be as the drain piping shown on the Drawings.
B. Finished and Unfinished Walls, CO-2: Provide duracoated cast iron cleanout tea with gas and
watertight ABS tapered thread plug and a square, smooth nickel-bronze secured wall access
cover and frame, similar to Zurn Model Z1447.
C. Outside Location: Provide duracoated, cast iron cleanout with gas and watertight ABS
tapered thread plug, an adjustable housing, and heavy-duty tractor-type cover with vandal-
proof screws, cast flush in a 16” square by 6” thick concrete pad in non-surface areas.
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2.5 FIRE HYDRANTS
A. Provide fire hydrants according to the Standard Detail at the locations indicated on the
Drawings.
2.6 YARD HYDRANTS AND HOSE STATIONS
A. Provide yard hydrants according to the Standard Detail at the locations indicated on the
Drawings.
B. Provide hose station according to the Standard Detail at the locations indicated on the
Drawings. Hose station shall consist of hydrant, hose of the size and type indicated, spray
nozzle, and bracket.
PART 3 - EXECUTION
3.1 INSTALLTION
A. Floor Drains: Install of the size and at the locations shown on the Drawings and in
accordance with manufacturer’s instructions. Provide hub drains at equipment for the
collection of waste water.
B. Trench Drains: Install to the lines and grades shown on the Drawings and in accordance with
manufacturer’s instructions.
C. Cleanouts:
1. Provide drainage lines with properly specified cleanouts. Locate cleanouts in runs not
more than 90 feet on centers or as required by local authority having jurisdiction.
2. Provide cleanouts at the base of each soil or waste stack and wherever necessary to
make accessible all parts of the drainage soil or waste systems.
3. Extend cleanouts within chases to near wall and provide wall access cover compatible
with wall construction.
4. Provide cleanouts of required size with flashing flange where installed with membrane
water proofing.
D. Fire Hydrants, Yard Hydrants, Hose Stations: Provide where shown on the Drawings and in
accordance with Drawings Detail.
END OF SECTION
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SECTION 40 01 05
FIELD TESTING OFPIPING SYSTEMS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section Includes:
Provide all necessary labor, materials and equipment, including test pumps and
gauges, as well as temporary valves and piping to perform the testing operations of
piping systems as specified herein.
All piping systems will be tested. If demonstrated workmanship on one or more tests
show that lines are sufficiently watertight, the ENGINEER may waive remaining
testing on any given type or section of line.
CONTRACTOR'S Responsibility:
Take such precautions as required to prevent damage to lines and
appurtenances being tested.
Repair any damage resulting from tests.
Repair and retest all items which do not pass the tests as specified herein.
Conduct all tests in the presence of the ENGINEER, and to the satisfaction of
the ENGINEER and all State and local authorities having jurisdiction.
All necessary pumps, water, pipe connections, meters, gauges, and any
necessary apparatus to perform and conduct the tests shall be furnished by the
CONTRACTOR. CONTRACTOR shall furnish all necessary equipment and make
all tests at CONTRACTOR'S expense without separate measurement and
payment, but said expense shall be subsidiary to installation of pipe.
Test pressures are specified in Test Pressures for Pressure Lines in Part 3 of this
Section.
Water used for testing purposes shall be potable water only.
Related Sections:
Section 33 05 61“Manholes" for testing requirements for manholes.
1.3DEFINITIONS AND REFERENCES
Definitions:
Gravity lines: shall refer to PVC, clay pipe, reinforced concrete (non-cylinder-type)
pipe, and other such pipes designed to normally operate in a partially full condition.
Pressure lines: shall refer to ductile iron, PVC, RCCP, steel, and other such pipes
designed to operate in a full condition, with the system's energygrade line at or
above the top of the pipe during normal operating conditions.
FRP: Fiberglass-reinforced plastic.
LLDPE: Linear low-density, polyethylene plastic.
PE: Polyethylene plastic.
CPVC: Chlorinated polyvinyl chloride plastic.
PVC: Polyvinyl chloride plastic.
References:
American Water Works Association (AWWA):
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C 600 –Standard for Installation of Ductile-Iron Water Mains and Their
Appurtenances
M 23 –PVC Pipe Design and Installation
ASTM International (ASTM):
C 924 –Practice for Testing Concrete Pipe sewer Lines by Low-Pressure Air
Test Method
F 1417 –Test Method for Installation Acceptance of Plastic Gravity Sewer Lines
Using Low-Pressure Air
Unibell PVC Plastic Pipe Association, “Handbook of PVC Pipe: Design and Construction,
Fourth Edition”
1.4SUBMITTALS
Shop Drawings:
Submit a description of proposed testing methods, procedures, and apparatus for
review prior to testing.
Submit description of weir and weir tables to be used in infiltration test, ifapplicable.
Field Quality-Control Reports:
Submit a certified test report for each test to ENGINEER certifying the test pressures,
duration of the test, leakage and pertinent observations and comments.
PRODUCTS
2.1TEST EQUIPMENT
Test equipment shall be selected, obtained, and maintained by the CONTRACTOR. All
gauges shall be calibrated prior to beginning testing and as often as is necessary to provide
accurate, reliable information.
EXECUTION
3.1GENERAL REQUIREMENTS
Obtain the ENGINEER’S approval of proposed testing methods, procedures, and apparatus,
before performing any test. Upon receipt of the ENGINEER’S approval, submit a schedule of
testing dates and times at least 24-hours in advance of testing.
Inspect interior of piping to determine whether line displacement or other damage has
occurred. Inspect after approximately 24 inches of backfill is in place, and again at
completion of Project.
Submit separate reports for each system inspection.
Defects requiring correction include the following:
Alignment: Less than full diameter of inside of pipe is visible between
structures.
Deflection: Flexible piping with deflection that prevents passage of ball or
cylinder of size not less than 92.5 percent of piping diameter.
Crushed, broken, cracked, or otherwise damaged piping.
Infiltration: Water leakage into piping.
Exfiltration: Water leakage from or around piping.
Replace defective piping using new materials, and repeat inspections until defects are
within allowances specified.
Reinspect and repeat procedure until results are satisfactory.
Test new piping systems, and parts of existing systems that have been altered, extended, or
repaired, for leaks and defects.
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Do not enclose, cover, or put into service before inspection and approval.
Test completed piping systems according to authorities having jurisdiction.
Schedule tests and inspections by authorities having jurisdiction with at least 24
hours' advance notice.
Submit separate report for each test.
Gravity-Flow Sewage and Drainage Piping: Test according to requirements of
authorities having jurisdiction, UNI-B-6, and the following:
Exception: Piping with soil tight joints unless required by authorities having
jurisdiction.
Option: Test plastic piping according to ASTMF1417.
Option: Test concrete piping according to ASTMC924.
Manholes: Test manholes in accordance with Section 33 05 61“Manholes.”
Force-Main and Pressure Piping: Perform hydrostatic test after thrust blocks,
supports, and anchors have hardened. Test at pressure not less than 1-1/2 times the
maximum system operating pressure, but not less than 150 psig.
Ductile-Iron Piping: Test according to AWWAC600, "Hydraulic Testing"
Section.
PVC Piping: Test according to AWWAM23, "Testing and Maintenance"
Chapter.
3.2CLEANING, TESTING, AND DISINFECTION OF POTABLE WATER LINES
Piping Tests: Conduct piping tests before joints are covered and after concrete thrust blocks
(when allowed) have hardened sufficiently. Fill pipeline 24-hours before testing and apply
test pressure to stabilize system. Use only potable water.
Hydrostatic Tests: Test at not less than one-and-one-half times working pressure for two
hours.
Increase pressure in 50-psig increments and inspect each joint between increments.
Hold at test pressure for 1 hour; decrease to 0 psig. Slowly increase again to test
pressure and hold for 1 more hour. Maximum allowable leakage is 2 quarts per hour
per 100 joints. Remake leaking joints with new materials and repeat test until
leakage is within allowed limits.
Prepare reports of testing activities.
Clean and disinfect water-distribution piping as follows:
Purge new water-distribution piping systems and parts of existing systems that have
been altered, extended, or repaired before use.
Fire-protection water piping not connected to potable water supply: Use purging and
disinfecting procedure prescribed by authorities having jurisdiction or, if method is not
prescribed by authorities having jurisdiction, use procedure described in NFPA24 for
flushing of piping. Flush piping system with clean, potable water until dirty water
does not appear at points of outlet.
Fire-protection water piping connected to potable water supply: Use purging and
disinfecting procedure prescribed by authorities having jurisdiction or, if method is not
prescribed by authorities having jurisdiction, use procedure described in AWWAC651
or do as follows:
Fill system or part of system with water/chlorine solution containing at least 50
ppm of chlorine; isolate and allow standing for 24 hours.
Retain last subparagraph above or first subparagraph below.
Drain system or part of system of previous solution and refill with
water/chlorine solution containing at least 200 ppm of chlorine; isolate and
allow standing for 3 hours.
After standing time, flush system with clean, potable water until no chlorine
remains in water coming from system.
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Submit water samples in sterile bottles to authorities having jurisdiction.
Repeat procedure if biological examination shows evidence of contamination.
Prepare reports of purging and disinfecting activities.
3.3TESTING OF PRESSURE LINES (EXCEPT POTABLE WATER LINES)
General:
Allow concrete blocking (when allowed) to cure for at least 28 days before testing.
Backfill and compact soil behind all blocking.
Backfill over pipe to extent necessary to restrain the piping. Backfill shall extend to
within 1-foot of proposed final grade.
Conduct water leakage test after completing hydrostatic pressure tests.
Lines which fail to hold the specified test pressure for at least two hours or which
exceed an allowable leakage rate specified below, shall be repaired to the satisfaction
of the ENGINEER and retested at the CONTRACTOR'S expense.
System shall be tested in sections between valves and shall not exceed 2,000feet
unless authorized by ENGINEER.
Procedures for Hydrostatic Pressure Tests:
Slowly fill isolated section of line with water.
Insure that all air has been expelled through air and vacuum release valves, taps, or
connections shown on Plans for permanent piping, valves, or accessories. Do not
make additional taps solely for air expulsion purposes unless approved by ENGINEER.
No additional compensation will be made for additional taps.
Apply specified test pressure based on the elevation of the lowest section of line
under test and correctedto elevation of test gauge. Duration of test shall be two
hours.
Allow concrete pipe to stand full of water at least 12-hours before starting leakage
test.
At the end of the two hours of the test, the entire route of the pipeline shall be
inspected to locate any leaks or breaks. Any defective joints, cracked or defective
pipe, fittings, or valves discovered in consequence of this pressure test shall be
removed and replaced with sound material in the manner provided and the test shall
be repeated until satisfactory results are obtained. Any and all noticeable leaks shall
be repaired regardless of whether the actual leakage is within the allowable. The
pipe shall be retested over a period of two hours.
All piping systems shall be tested for leakage by a hydrostatic pressure test. Lines
shall be filled slowly, with a maximum velocity of 1-foot per second, while venting all
air. If permanent air vents have not been installed, the CONTRACTOR shall install
corporation cocks at all high points to expel air during initial filling and testing of the
lines.
The duration of each leakage test shall be two hours unless otherwise specified, and
during the test the line shall be subjected to a continuous specified test pressure at
the lowest elevation.
Leakage is defined as the net quantity of water that must be supplied into the newly
laid pipe, or any valved section thereof, necessary to maintain pressure within 5-psi of
the specified leakage test pressure after the pipe has been filled with water and the
air in the pipeline has been expelled. No installation shall be accepted if the leakage
is greater than that determined by the following formula:
0.5
L = SD(P)
133,200
Where:
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L = allowable leakage in gallons per hour
D = nominal diameter of the pipe, inches
P = average test pressure during the leakage test, psig
S = length of pipe tested, in feet
The test pressure shall be applied by means of a pump connected to the pipe and to
an approved water container, or other approved method, for accurate measurement.
The test pressure shall be maintained (by additional pumping, if necessary) for the
specified time.
While the line is under pressure, the system and all exposed pipe, fittings, valves, and
hydrants shall be carefully examined for leakage. All defective elements shall be
repaired or replaced and the test repeated until all visible leakage has been stopped
and the allowable leakage requirements have been met.
On completion of tests, any newly installed, approved taps shall be tightly plugged
with brass fittings.
Thoroughly purge all compressed air lines after testing.
For low pressure air pipes use the pneumatic test method listed in paragraph3.5, using test
pressures listed in the Plans or as listed in paragraph 3.4.
3.4TEST PRESSURES FOR PRESSURE LINES
Piping shall be tested to pressures shown on Plans. If not shown, test to at least 1.5 x
operating pressure, with a minimum test pressure as follows:
All process piping shall be tested to 75-psi.
Pump discharge and force main to 200-psi.
Chemical piping to 100-psi.
Plant water and potable piping to 150-psi.
Drain and sewage lines using pressure pipe to 50 psi.
Low pressure air pipes to 25 psi.
High pressure air pipes to 200 psi.
3.5TESTING OF DRAINS, SEWERS, AND OTHER GRAVITY LINES
General:
For all pipe, the method of testing shall be an exfiltration test using either a
hydrostatic test or a pneumatic test. For any flexible, non-metallic or non-concrete
pipe, such as plastic (PVC, CPVC, PE, etc.) or fiber reinforced plastic pipe or similar
flexible pipe materials, a deflection test shall also be performed.
CONTRACTOR may make first test promptly after first section of line is laid and
backfilled. A section of pipe will normally be a run between two manholes, or
between a structure and the first manhole.
Do not lay additional piping of the type being tested until test of first section is
complete.
Do not perform any OWNER required leak test until backfill has been installed to
grade for a minimum of 30 days.
Individual leaks will ordinarily be revealed by looking through sewer (larger than 24-
inch diameter) with a light while ground water level is over sewer, during water
tamping operations, or immediately after water from exfiltration tests is emptied from
sewer.
Settlement in backfill during exfiltration testswill be taken as an indication of leakage.
Hydrostatic Exfiltration Test Procedure:
Seal ends of section being tested with watertight plugs.
Fill section with water 24-hours prior to start of test.
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Vent line during filling so that no air is trapped in line.
Leave outlets of stacks, inlets, and service lines exposed and unplugged until after
exfiltration test has been made.
Outlets terminating below level of test water surface to be temporarily extended
upward by installing lengths of pipe.
Measure leakage or exfiltration during test period by adding measured quantities of
water to maintain water level in test structure.
Quantity of water added to maintain water level is amount of leakage or exfiltration.
Test for at least two hours with minimum head of fourfeet measured above top
crown, inside pipe at upper end of section being tested. Allow for increase in height
due to ground water level, if any.
Storm sewer leads to be tested with water level at gutter grade.
After completion of satisfactory test, remove lengths of pipe added for test.
Allowable Leakage: Allowable leakage for exfiltration test in any individual section or
entire sewer line under construction shall not exceed 10 gallons per inch of inside
diameter per mile of pipe per 24 hours.
Low Pressure Air Joint Test:
All pipe joints shall be tested in accordance with this section.
Equipment shall be the product of manufacturers having more than five year’s regular
production of successful joint testers. Joint tester shall be as manufactured byChane
Industrial, Inc., of Edina, Minnesota, or equal.
Testing shall be performed on all joints after backfill has been installed and properly
compacted, and as installation progresses. At no time shall pipe installation exceed
100 feet beyond the last joint tested.
Joints failing to meet the requirements of this test should be repaired to the
satisfaction of the Engineer or the defective pipe shall be replaced. Rejected pipe
shall be removed from the project. Installation shall be stopped until defective joints
are repaired or replaced.
The testing equipment shall be assembled and positioned over the center of the pipe
joint and the end element tubes inflated to a maximum of 25 psi.
Pressurize the center joint test area to 4.0 psig and allow the temperature and
pressure to stabilize at the minimum of 2.5 psig for a period of 2.0minutes prior to
testing.
To test, adjust the pressure to 4.0 psig and measure the time required to decrease
the pressure from 4.0 psig to 2.0 psig.
The joint is acceptable if the time for the pressure to drop from 4.0psig to 2.0psig is
greater than 15 seconds.
Pneumatic Test Method (Air Test):
Air tests shall be made by the pressure drop versus time method, in accordance with
UNI-B-6, “Recommended Practice for Low-Pressure air testing of Installed Sewer
Pipe.”
Equipment: The equipment used shall meet the following minimum requirements:
Pneumatic plugs shall have a sealing length equal to or greater than the diameter of
the pipe to be inspected.
Pneumatic plugs shall resist internal test pressures without requiring external bracing
or blocking.
All air used shall pass through a single control panel.
Three individual hoses shall be used for the following connections:
From the control panel to pneumatic plugs for inflation.
From thecontrol panel to a sealed line for introducing the low-pressure air.
From a sealed line to control panel for continually monitoring the air pressure
rise in the sealed line.
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Air compressor of adequate capacity for charging the system.
Procedures: All pneumatic plugs shall be seal-tested before being used in the actual
test installation. One length of pipe shall be laid on the ground and sealed at both
ends with the pneumatic plugs to be checked. Air shall be introduced into the plugs
to 25 psig. The sealed pipe shall be pressurized to 5 psig. The plugs shall hold
against this pressure without bracing and without movement of the plugs out of the
pipe.
After a manhole-to-manhole reach of pipe has been backfilled and the pneumatic
plugs have been checked by the above-mentioned procedure, the plugs shall be
placed in the line at each manhole and inflated to 25 psig. Low pressure air shall be
introduced into this sealed line until the internal air pressure reaches 4 psig. Allow at
least two minutes for theair temperature to stabilize, adding only the amount of air
required to maintain pressure.
If the pipe to be tested is submerged in ground water, insert a pipe probe by boring
or jetting into the backfill material adjacent to the center of the pipe, and determine
the pressure in the probe when air passes slowly through it. This is backpressure due
to ground water submergence over the end of the probe. All gauge pressure in the
test should be increased by this amount. After the stabilization period (3.5 psig of
minimum pressure in the pipe) start stopwatch. Determine time in seconds that is
required for the internal air pressure to reach 2.5psig.
Allowable Leakage: For sections of pipe less than 36-inch average inside diameter,
the minimum time allowable for the pressure to drop from 3.5 pounds per square inch
gauge to 2.5 pounds per square inch gauge shall be computed from the following
equation:
T = 0.0850(D)(K)/(Q)
Where:
T = shortest time for pressure to drop 1.0 pound per square inch gauge in
seconds
K = 0.000419(D)(L), but not less than 1.0
D = average inside diameter in inches
L = length of line in feet of same pipe size being tested
Q = rate of loss, 0.0015 cubic feet per minute per square foot internal surface
shall be used.
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Since a K value of less than 1.0 shall not be used, there are minimum testing times
for each pipe diameter as follows:
Table No. 1
Minimum Testing Times
Length forTime for
Pipe DiameterMinimum Time
Minimum TimeLonger Length
(inches)(seconds)
(feet)(seconds)
63403980.855 (L)
84542981.520 (L)
105672393.374 (L)
126801993.419 (L)
158501595.342 (L)
1810201337.693 (L)
21119011410.471 (L)
24136010013.676 (L)
2715308817.309 (L)
3017008021.369 (L)
3318707225.856 (L)
3.6PIPELINE REPAIR
Leaks and loss in test pressure constitute defects that must be repaired. Replace leaking
piping using new materials, and repeat testing until leakage is within allowances specified.
3.7MANHOLE TESTING
Manholes shall be tested separately and independently of the wastewater lines in
accordance with Section33 05 61“Manholes.” Unless otherwise specified or determine by
OWNER’S requirements manhole testing shall by Water Exfiltration Test.
END OF SECTION
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SECTION 40 05 05
PIPING SYSTEM,BASIC MATERIALS AND METHODS
GENERAL
1.1SUMMARY
Piping materials and installation methods common to the piping system Sections of
Division40and includes joining materials, piping specialties, and basic piping installation
instructions.
All exposed, submerged, and buried process, plant and station piping including new
piping systems and modifications to existing systems.
Raw water, potable water, sanitary sewers, storm drains and culverts serving plant or
station as shown on Drawings.
Section Includes:
Pipe Joining Materials
Transition Fittings
Insulating Flanges,Couplingsand Unions
Connectors and Couplings
Pipe Sleeves
Expansion Joints
Related Sections:
Division 40for related piping, valves, and support systems.
1.2REFERENCES
Preselection Drawings and general provisions of the Contract, including Preselection Special
Conditions and Division 01 Specification Sections, apply to this Section.
Standards:
American National Standards Institute (ANSI):
B9.1 Standard Safety Code for Mechanical Refrigeration
B31.3 Power Piping Code
B31.3ProcessPipingCode
B31.9 Building Service Piping Code
ASTM International (ASTM):
A 53 –Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded
and Seamless
B 32 –Specification for Solder Metal
B 813 –Specification for Liquid and Paste Fluxes for Soldering Copper and
Copper Alloy Tube
B 828 –Practice for Making Capillary Joints by Soldering of copper and Copper
AlloyTube and fittings
C 1173 –Specification for Flexible Transition Couplings for underground Piping
Systems
D 1785 –Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40,
80, and 120
D 2564 –Specification for Solvent Cements for Poly(Vinyl Chloride) (PVC)
Plastic Piping systems
D 2672 –Specification for Joints for IPS PVC Pipe Using Solvent Cement
D 2846 –Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Hot-
and Cold-Water distribution Systems
D 2855 –Practice for Making Solvent-Cemented Joints with Poly(Vinyl Chloride)
(PVC) Pipe and Fittings
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D 3139 –Specifications for Joints for Pressure Pipes Using Flexible Elastomeric
Seals
D 3212 –Specification for Joints for Drain and Sewer Pipes using Flexible
Elastomeric Seals
E 814 Test Method for Fire Tests of Through-Penetration Fire Stops
F 402 –Practice for Safe Handling of Solvent Cements, Primers, and Cleaners
Used for Joining thermoplastic Pipe and Fittings
F 656 –Specifications for Primers for Use in Solvent Cement Joints of Poly
(Vinyl Chloride) (PVC) Plastic Pipe and Fittings
F 493 –Specification for Solvent Cements for Chlorinated Poly (Vinyl Chloride)
(CPVC) Plastic Pipe and Fittings
F 593 –Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs
F 594 –Specification for Stainless Steel Nuts
American Society of Mechanical Engineers (ASME):
A13.1 Scheme for Identification of Piping Systems
B1.20.1 Pipe Threads, General Propose, Inch
B16.21 Nonmetallic Flat Gaskets for Pipes Flanges
B18.2.1 Square andHex Bolts and Screws, Inch Series
American Welding Society (AWS):
A5.8 Specification for Filler Metals for brazing and Braze Welding
D1.1 Structural Welding Code Steel
D10.12 Guide for Welding Mild Steel Pipe
American Waterworks Association (AWWA):
C110 –Standard for Ductile-Iron and Gray-Iron Fittings, 3 In. Through 48 In.
(76 mm Through 1,219 mm) for Water
C219 –Standard for Bolted, Sleeve-Type Couplings for Plain-End Pipe
National SanitationFoundation (NSF):
NSF/ANSI 61 –Drinking Water Components –Health Effects
Definitions:
Piping Systems: Includes all piping, fittings, valves, specials, hangers and supports,
and related items required for a complete piping system.
Ferrous Metal: Iron, steel, stainless steel, and alloys with iron as principal component.
Nonmetallic: PVC, CPVC, PE, HDPE, and FRP.
Nonferrous Metals: Copper
Wetted or Submergence:
Submerged, or less than one foot above the maximum liquid surface of water
holding structures.
Below top of channels, under cover of slabs of channels or tanks.
In other damp or covered locations (e.g., vaults, wetwells, utility corridors,
etc.)
Exposed or Atmospherically Exposed PipingSystems: All piping systems exposed to
the atmosphere (not buried, submerged, wetted or embedded). This designation
includes insulated piping inside chases, or piping hidden from view.
Texas Administrative Code (TAC):
Chapter 217 –Design Criteria for Sewerage Systems
Chapter 290 Subchapter D –Rules and Regulations for Public Water Systems
1.3SYSTEM DESIGN DESCRIPTION
General:
The Drawings and Specifications are not all inclusive of explicit piping details; provide
piping in accordance with the laws and regulations and intended use, including:
Power Piping: ANSI/ASME B31.1 Code.
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Process Piping: ANSI/ASME B31.3 Code.
Building Service Piping: ANSI/ASME B31.9 Code, as applicable.
Sanitary Building Drainage and Vent Systems: ICBO/APMO Uniform Plumbing
Code.
Buried Piping: Provide to be suitable for design conditions as follows:
H20-S16 traffic load (AASHTO Standard Highway Specifications for Bridges)
with 1.5 impact factor.
Piping both with and without internal pressure.
Hangers and Support Systems: Provide an engineered system in accordance with
Section 40 05 07“Hangers and Supports for Process Piping.”
Pressure Testing and Disinfection of Pipelines: Refer to Section 400105“Field
TestingofPiping Systems” for testing of gravity and pressure piping systems; the
disinfection of potable water systems; and to the individual piping system Sections for
specific requirements.
Design Requirements:
The configuration and layout of various piping systems are shown in the Drawings.
The types of pipe and joints, and embedment (if buried) to be used for each system
are shown on the drawings or included in the appropriate specification Sections.
In certain locations, pipe supports, anchors, and expansion joints have been indicated
on the drawings, but no attempt has been made to indicate every pipe support,
anchor, and expansion joint.
It shall be the CONTRACTOR'S responsibility to provide a complete system of pipe
supports, to provide expansion joints, and to provide restraints and anchor all piping,
in accordance with the requirements set forth herein. Additional pipe supports may
be required adjacent to expansion joints, couplings, or valves.
Pipe and fittings shown on yard piping drawings are general in nature. CONTRACTOR
shall determine exact lengths and fittings required and make field adjustments
necessary to complete piping and avoid conflicts.
Changes to the plan and profile of piping shall be submitted to ENGINEER for
approval.
Restrained Pipe and Fitting Joints, Buried Piping:
Restrained joints shall be used for a sufficient distance from each bend, tee, elbow,
plug, or other fitting to resist thrust that will develop at the design pressure.
CONTRACTOR shall provide restraint length calculations in accordance with AWWA
M41 based on the laying conditions, soil conditions, depth of cover, and pressures to
determine the number of restrained joints that will be required.
For the purposes of thrust restraint, design pressures shall be the working pressure
shown, plus the additional surge allowance for potable water, service water, and
pump discharge piping. The design pressure shall be 1.5 times the design test
pressure indicated for all other piping.
1.4SUBMITTALS
Action Submittals
Product Data: Submit product data on each product item to be installed.
Shop Drawings: Provide shop drawings for piping systems, organized by plant areas
or individual piping systems. Prepare drawings to scale (1/4-inch = 1 foot 0 inch
minimum), with the following information:
Type of piping including materials, fittings, weights, linings, and coatings. A
code or key to product data sheet may be used.
Location and type of joints, fittings, taps, supports, restraint systems, kickers,
and blocking (as applicable). Identify by catalog number or shop drawing detail
number.
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Provide information on interior linings and exterior coatings.
Identify the exact number of restrained joints, as well as the length of
restrained joint piping for pressure buried piping.
Specials: Provide fabrication drawings for specials including fabricated fittings, wall
pipes, and wall sleeves. Show dimensions and materials of construction.
Before starting fabrication, CONTRACTOR shall provide ENGINEER with pipe design
calculations, the proposed engineered hanger and support systems, and specials,
which shall incorporate the following information:
Laying plan identifying all restrained joints, details of standard pipe section,
special fittings, pipe supports, and bends.
Piping components shall be numbered or otherwise sequence designated.
Outlets and bends shall be made up into special lengths so that, when
installed, they will be located as indicated.
Each pipeand fitting shall be marked indicating class of pipe and location
number in pipe laying plan. Markings shall be coded to the Shop drawings.
Quality Control Submittals:
Welding certificates.
Field Test Reports: For each pressure testing of piping systems and field-testing
specified in other piping systems sections.
Affidavits:
Manufacturer’s Certificate of Compliance with reference standards.
Laboratory Testing Equipment: Certified calibrations, manufacturer’s product
data and test procedures.
Certified welding inspection and test results.
1.5QUALITY ASSURANCE
Steel Support Welding: Qualify procedures and personnel according to AWSD1.1/D1.1M,
"Structural Welding Code."
Steel Piping Welding: Qualify processes and operators according to ASME Boiler and
Pressure Vessel Code: SectionIX, "Welding and Brazing Qualifications."
Comply with provisions in ASMEB31 Series, "Code for Pressure Piping."
Certify that each welder has passed AWS qualification tests for welding processes
involved and that certification is current.
Welding procedures and testing shall comply with ANSI B31.1.0, “Standard Code for
Pressure Piping, Power Piping,” and the AWS Welding Handbook.
Soldering and Brazing Procedures shall conform to ANSI B9.1, “Standard Safety Code
for Mechanical Refrigeration.”
Comply with ASMEA13.1 for lettering size, length of color field, colors, and viewing angles
of identification devices.
1.6DELIVERY, STORAGE, AND HANDLING
Comply with the requirements of Section 01 60 00 “Product Requirements” and as described
in the following paragraphs.
Acceptance at Site:
General: Comply with manufacturer's instructions for unloading, storage, and handling
at Project site.
Delivery and Handling:
Do not deliver piping materials to project site prior to ENGINEER'S review of
required submittals.
Unload and handle piping materials using proper material handling equipment.
Use heavy canvas or nylon slings to liftpipe and fittings to protect coatings.
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Do not drop, roll, skid piping materials.
Take such additional precautions as necessary to avoid damaging piping
materials and coatings thereon.
Storage and Protection:
Store piping materials in a manner that will reduce risk of damage.
Block piping materials to prevent rolling.
Protect materials from weather and sun as recommended by the manufacturer.
Provide factory-applied plastic end-caps on each length of pipe and tube, except for
concrete, corrugated metal, hub-and-spigot, and clay pipe. Maintain end-caps
through shipping, storage and handling to prevent pipe-end damageand prevent
entrance of dirt, debris, and moisture.
Protect stored pipes and tubes. Elevate above grade and enclose with durable,
waterproof wrapping. When stored inside, do not exceed structural capacity of the
floor.
Protect flanges, fittings, and specialties from moisture and dirt by inside storage and
enclosure, or by packaging with durable, waterproof wrapping. Attach protectors over
entire gasketed surface of flanges.
Flexible piping shall be stored in shaded area 24-hours prior to installation.
1.7PROJECT CONDITIONS
Field Measurements: Verify actual dimensions of openings, construction contiguous with
work, and related items by field measurements before fabrication.
Flange Coordination: Coordinate the dimensions, hole drillings and type of flange face (flat
or raised) of the flanges furnished with companion flanges of valves, pumps and equipment
to be connected to or installedin the piping.
NSF Certified: All surfaces and materials in contact with wateror in contact with a chemical
being added to water that is being treated for potable water use and conveyance, shall
comply with the requirements of the Safe Drinking Water Act and shall conform to NSF-61.
Product shall bear the mark or seal of an accredited testing laboratory.
1.8COORDINATION
Coordinate installation of required supporting devices and set sleeves in poured-in-place
concrete and other structural components as they are constructed.
Coordinate installation of identifying devices after completing covering and painting if
devices are applied tosurfaces.
Coordinate size and location of concrete bases. Formwork, reinforcement, and concrete
requirements are specified in Division3.
Coordinate installation of piping systems with other trades; such as electrical,
instrumentation, fire protection, and HVAC ducts.
PRODUCTS
2.1PIPING
As specified in the variousDivision 40 Sections,the Piping Schedule, and as shown on the
Drawings.
Diameters Shown:
Standardized Products: Nominal Size.
Fabricated Steel Piping (Except Cement-Lined): Outside diameter, ASME B36.10M.
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2.2PIPEJOINING MATERIALS
Pipe-Flange Gasket Materials: Suitable for chemical and thermal conditions of piping system
contents.
ASMEB16.21, nonmetallic, flat, asbestos free, 1/8-inch maximum thickness, unless
otherwise indicated.
Full-Face Type: For flat-face, Class125, cast-iron and cast-bronze flanges.
Narrow-Face Type: For raised-face, Class250, cast-iron and steel flanges.
AWWAC110, rubber, flat face, 1/8 inch thick, unless otherwise indicated; and full-
face or ring type, unless otherwise indicated.
Flange Bolts and Nuts:
ASMEB18.2.1, carbon steel, unless otherwise indicated.
Exposed: ASTM A307, Grade B, hex head bolts; ASTM A563, Grade A or B, hex head
nut; and ASTM F436 hardened steel washers. Corten acceptable for mechanical
joints.
Buried: ASTM A193 or ASTM A320, Type 316 stainless steel bolts; ASTM A194, Type
316, hex head nuts/ and washers of the same material as bolts.
Wetted and Submerged: ASTM A193 or ASTM A320, Type 316 stainless steel bolts;
ASTM A194, Type 316, hex head nuts/ and washers of the same material as bolts.
Segmented Mechanical Couplings: Provide when designated on the Drawings or as an option
to flanges for above ground piping, segmented mechanical couplings may be used.
Housing: Ductileiron conforming to ASTM A-536, grade 65-45-12, with orange
enamel coating.
Coupling Gasket: Grade “E” EDPM.
Bolts and Nuts: ASTM A193 or ASTM A320, Type 316 stainless steel bolts; Heat-
treated plated carbon steel, trackhead meeting physical and chemical requirements of
ASTM A-449 and physical requirements of ASTM A-183.
Victaulic Style 77 standard flexible couplings or equivalent.
Plastic, Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping
system manufacturer, unless otherwise indicated.
Solder Filler Metals: ASTMB32, lead-free alloys. Include water-flushable flux according to
ASTMB813.
Brazing Filler Metals: AWSA5.8, BCuPSeries, copper-phosphorus alloys for general-duty
brazing, unless otherwise indicated; and AWSA5.8, BAg1, silver alloy for refrigerant piping,
unless otherwise indicated.
Welding Filler Metals: Comply with AWSD10.12/D10.12M for welding materials appropriate
for wall thickness and chemical analysis of steel pipe being welded.
Solvent Cements for Joining Plastic Piping:
CPVC Piping: ASTMF493.
PVC Piping: ASTMD2564. Include primer according to ASTMF656.
Fiberglass Pipe Adhesive: As furnished or recommended by pipe manufacturer.
2.3TRANSITION FITTINGS
Transition Fittings, General: Same size as, and with pressure rating at least equal to and
with ends compatible with, piping to be joined.
Transition Couplings NPS1-1/2 and Smaller:
Underground Piping: Manufactured piping coupling or specified piping system fitting.
Aboveground Piping: Specified piping system fitting.
AWWA Transition Couplings NPS2 and Larger:
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Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Cascade Waterworks Mfg. Co.
Dresser, Inc.; DMD Div.
Ford Meter Box Company, Inc. (The); Pipe Products Div.
JCM Industries.
Smith-Blair, Inc.
Viking Johnson.
ROMAC
Description: AWWAC219, metal sleeve-type coupling for underground pressure
piping.
Plastic-to-Metal Transition Fittings:
Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Spears Manufacturing Co.
Description: CPVC and PVC one-piece fitting with manufacturer's Schedule80
equivalent dimensions; one end with threaded brass insert, and one solvent-cement-
jointor threaded end.
Plastic-to-Metal Transition Unions:
Available Manufacturers: Subject to compliance withrequirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Colonial Engineering, Inc.
NIBCO INC.
Spears Manufacturing Co.
Description: CPVC and PVC four-part union. Include brassor stainless-steel threaded
end, solvent-cement-jointor threaded plastic end, rubber O-ring, and union nut.
Flexible Transition Couplings for Underground Nonpressure Drainage Piping:
Available Manufacturers: Subject to compliance with requirements,manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Cascade Waterworks Mfg. Co.
Fernco, Inc.
Mission Rubber Company.
Plastic Oddities.
Description: ASTMC1173 with elastomeric sleeve ends same size as piping to be
joined, and corrosion-resistant metal band on each end.
2.4INSULATING FLANGES, COUPLINGS AND UNIONS
Dielectric Fittings, General: Assembly of copper alloy and ferrous materials or ferrous
material body with separating nonconductive insulating material suitable for system fluid,
pressure, and temperature.
Dielectric Unions:
Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Capitol Manufacturing Co.
Central Plastics Company.
Epco Sales, Inc.
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Hart Industries, International, Inc.
Watts Water Technologies, Inc.
Zurn Plumbing Products Group; Wilkins Div.
Description: Factory fabricated, union, NPS2 and smaller.
Pressure Rating: 150 psig minimum at 180 degF unless otherwise specified.
End Connections: Solder-joint copper alloy and threaded ferrous; threaded
ferrous.
Dielectric Flanges:
Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Capitol Manufacturing Co.
Central Plastics Company.
Epco Sales, Inc.
Watts Water Technologies, Inc.
Description: Factory-fabricated, bolted, companion-flange assembly, NPS2-1/2 to
NPS4 and larger.
Pressure Rating: 150 psig minimum unless otherwise specified.
End Connections: Solder-joint copper alloy and threaded ferrous; threaded
solder-joint copper alloy and threaded ferrous.
Dielectric-Flange Kits:
Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Advance Products & Systems, Inc.
Calpico, Inc.
Central Plastics Company.
Pipeline Seal and Insulator, Inc.
Description: Non-conducting materials for field assembly of companion flanges,
NPS2-1/2 and larger.
Pressure Rating: 150 psig minimum unless otherwise specified.
Gasket: Neoprene or phenolic.
Bolt Sleeves: Phenolic or polyethylene.
Washers: Phenolic with steel backing washers.
Dielectric Couplings:
Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Calpico, Inc.
Lochinvar Corporation.
Description: Galvanized-steel coupling with inert and noncorrosive, thermoplastic
lining, NPS3 and smaller.
Pressure Rating: 300 psig at 225 degF unless otherwise specified.
End Connections: Threaded.
Dielectric Nipples:
Available Manufacturers: Subject to compliance with requirements, manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
Perfection Corporation.
Precision Plumbing Products, Inc.
Victaulic Company.
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Description: Electroplated steel nipple with inert and noncorrosive, thermoplastic
lining.
Pressure Rating: 300 psigat 225 degF unless otherwise specified.
End Connections: Threaded or grooved.
2.5CONNECTORS AND COUPLINGS
General: Unless otherwise specified;
Type 316 stainless steel bolts, fasteners, tie rods and accessories are required for
connectors intended for buried, wetted, or submerged service.
Carbon steel bolts, fasteners, tie rods and accessories are required in exposed
atmospheric service. Coat items in accordance with Section09 91 00 “Painting and
Protective Coatings.”
Elastomer Bellows Connector:
Type: Fabricated spool, with single filled arch.
Materials: Nitrile tube and neoprene cover.
End Connections: Flange, 125-lb ANSI B16.1 standard, with elastomeric face and steel
retaining rings.
Working Pressure: 190 psig minimum, size 12-inch and smaller.
Thrust Restraint: Manufacturer designed control rods, fasteners, and accessories to
limit travel of elongation and compression.
Manufacturers and Products:
Garlock; Style 204
Goodall rubber Co.
General Rubber Corp.
Flexible Type Couplings (Steel and Stainless Steel Pipe):
Design: Provide thrust ties across flexible couplings.
Body and Middle ring: Carbonor Type 316stainless steel.
Followers: Ductile iron, malleable ironorType 316stainless steel.
Bolts: Carbon steelor Type 316 stainless steel.
Gaskets: EPDM
Materials of construction of coupling, closure plates, end rings, and fasteners to
match piping materials on which coupling is employed, as well as whether it is
exposed, wetted or submerged service.
Manufacturer and Product:
Dresser; Style 128
Smith-Blair; Style 912
Split Sleeve Couplings (Steel and Stainless Steel Pipe):
Design: Double arch, with built-in thickened shoulders. Full joint restraint achievedfor
two times test pressure by weld-on end rings. Closure plates and sealing pad integral
with coupling.
Gaskets: EDPM O-ring style.
Joint Deflection: Up to 2 degree.
Carbon steel metal components to have factory-applied fusion bonded epoxy coating
(7 MDFT).
Materials of construction of coupling, closure plates, end rings, and fasteners to
match piping materials on which coupling is employed, as well as whether it is
exposed, wetted or submerged service.
Manufacturer and Product: Victaulic, Inc.;Depend-O-Lok Model FxF, Type 2 Coupling,
or equal.
Flanged Coupling Adapters (FCA) (Ductile Iron and Steel Pipe):
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Design: Provide thrust across flexible coupling adapters.Restraint shall terminate at a
flange or anchor studs attached to the pipe exterior by weldedconnections or using a
slip on restraint flange.
Body: Carbon steel conforming to AWWA C207.
Flange: AWWA C207 or ANSI Standards.
Bolts: Carbon steelor 316 stainless steel.
Gaskets: EDPM.
Carbon steel metal components to have factory-applied fusion bonded epoxy coating
(7 MDFT).
Materials of construction of coupling, closure plates, end rings, and fasteners to
match piping materials on which coupling is employed, as well as whether it is
exposed, wetted or submerged service.
Manufacturer and Product:
Dresser; Style 128
Smith-Blair; Style 912
Wedge Action Restraints (Ductile Iron and PVC Pipe):
Design: Wedges and wedge actuating components are incorporated into the design of
the follower gland.
Material: Ductile iron, ASTM A536, Grade 65-45-12; wedges BHN 370 minimum.
Nuts: Designed with torque-limiting twist-off nuts, exposing a bolt head sized to
permit adjustment and removal of joint restraint.
Chemical and nodularity test shall be performed as recommended by Ductile Iron
Society on a per ladle basis.
Traceability: Provide material traceability records.
Coating:
Wedge Assembly: Two coats of liquid Xylan fluoropolymer, heat cured.
Casting Body: Polyester based powder, electrostatically applied and heat cured,
providing corrosion, impact and UV protection.
Approvals:
Ductile Iron Pipe Restraints:
Underwriters Laboratories: Size 3-inch through 24-inch.
Factory Mutual: Size 3-inch through 12-inch.
PVC Pipe Restraints:
Underwriters Laboratories: Size 4-inch through 12-inch.
Factory Mutual: Size 4-inch through 12-inch.
Size 4-inch through 24-inch comply with ASTM F1674.
Manufacturer and Product:
Ductile Iron Pipe: EBAA Iron Megalug 1100 series.
PVC Pipe: EBAA Iron Megalug 2000 PVC series.
2.6PIPE SLEEVES
Mechanical sleeve seals for pipe penetrations:
Pipeto wall/casing penetration closures shall be modular mechanical type, consisting
of interlocking synthetic rubber links shaped to continuously fill the annular space
between pipe or conduit and wall/casing opening. Once expanded, the mechanical
seal shallprovide a watertight seal.
Elastomeric element size and material shall be selected per manufacturer
recommendations. Assemble with ASTM A276, Type 316 stainless steel bolts and
nuts.
Pressure end plates shall be either Type 316 stainless steel or manufactured of glass
reinforced plastic, with a minimum tensile strength of 20,000 psi.
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Sized: According to manufacturer’s recommendations for the size of pipe shown; to
provide a watertight seal between pipe and wall sleeve opening.
Available Manufacturers:
Advance Products & systems, Inc. (Innerlynx)
Pipeline Seal & insulator, Inc. (Link-Seal)
Galvanized-Steel Sheet Sleeves: 0.0239-inch minimum thickness; round tube closed with
welded longitudinal joint.
Steel Pipe Sleeves: ASTMA53/A53M, TypeE, GradeB, Schedule40, galvanized, plain
ends.
Cast-Iron Sleeves: Cast or fabricated "wall pipe" equivalent to ductile-iron pressure pipe,
with plain ends and integral waterstop, unless otherwise indicated.
Molded PVC Sleeves: Permanent, with nailing flange for attaching to wooden forms.
PVC Pipe Sleeves: ASTMD1785, Schedule40.
Molded PE Sleeves: Reusable, PE, tapered-cup shaped and smooth outer surface with
nailing flange for attaching to wooden forms.
Insulated and Encased Pipe Sleeve: Conforming to Pipe Shields, Inc.; Models WFB<WFB-CS
and –CW Series, as applicable.
Seepage Ring: Provide a seepage ring in middle of wall sleeve as follows:
3/16-inch minimum thickness, centered between sleeve ends for water stoppage on
sleeves located in exterior or water bearing walls.
Outside Diameter: 3-inches grater that pipe sleeve outside diameter.
Continuously fillet weld on each side all around.
Voids between sleeves or core-drilled openings and pipe or conduit passing through fire
rated assembliesshall be fire stopped to comply with requirements of ASTM E 814.
2.7EXPANSION JOINTS
Elastomer Bellows:
Type: Reinforced, molded wide-arch.
End connections: Flanged, 125-lb ANSI B1.1 standard, with Type 316 stainless steel
retaining rings.
Washers: Over the retaining rings to provide a leak proof joint under test pressure.
Thrust Protection: Manufacturer designed and supplied control rods, fasteners, and
accessories to protect bellows from overextension at test pressures.
Tube and Bellows Arch Lining: EDPM.
Rated Temperature: 250ºF.
Rated Deflection and Pressure:
Lateral Deflection: 3/4-inch minimum.
Burst Pressure: four times rated pressure.
Compression Deflection at Minimum Pressure: 1/2-inch at 250 psig.
Manufacturer and Product:
Holz Rubber Company, Inc.
Mercer Rubber Co.; Series 500
General Rubber Corp.
Goodall Rubber Co.
2.8LININGS AND COATINGS
Interior Pipe Linings: Prepare, prime, and finish pipe interior in accordance the applicable
piping system Section 09 91 00 “Painting and Protective Coatings.”
Exterior coatings: Prepare, prime, and finish pipeexteriorin accordance the applicable
piping system Section 0991 00“Painting and Protective Coatings.”
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2.9IDENTIFICATION
Provide piping, valve, equipment, and related product identification devices in accordance
with Section10 90 00 “Identification, Stenciling, and Tagging.”
2.10HANGERS AND SUPPORTS
Provide hangers and supports as shown on the drawings and in accordance with Section 40
05 07“Hangers and Supports for Process Piping.”
EXECUTION
3.1GENERAL INSTALLATION REQUIREMENTS
CONTRACTOR shall be responsible for, develop, and comply with the trench safety plan and
a confined space entry plan.
CONTRACTOR shall provide a dewatering system of sufficient scope, size, and capacity to
control hydrostatic pressures and to lower, control, remove, and dispose of ground water
and permit excavation and construction to proceed on dry, stable subgrades complying with
the requirements of Section 31 23 19“Dewatering.”
Install all piping systems in accordance with the Drawings, Specifications, reviewed shop
drawings and manufacturer's installation instructions. Pipe and fitting materials shall comply
with the individual piping system Division 40 Sections.
Examine all piping materials prior to installation and replace items that are damaged or
otherwise defective.
CONTRACTOR shall mark actual flow line or top of pipe elevations and actual coordinates on
record drawings when pipelines are being installed.
Thoroughly clean inside of all piping, valves, and accessories, and outside of all materials
which will be exposed. Clean before installation and maintain in that condition until
accepted by OWNER.
Provide secure temporary caps or plugs over all pipe openings at the end of each day to
prevent foreign material from entering the piping systems. Brace pipe to prevent it from
floating.
Do not modify structures, equipment, or piping for the purpose of installing piping unless
specifically authorized by the ENGINEER.
All piping systems shall be cleaned and tested prior to making connections at structures and
to existing pipe systems. Small diameter pipes shall be flushed and large diameter pipes
shall have mandrels pulled or other acceptable verification furnished that pipes are clean
and no construction debris remains. Temporary blocking and forms used to grout inverts
and blockouts shall be removed and manholes and pipes shall be tested before payment will
be approved for the last 10percent of the respective pipe pay estimate items.
3.2PIPING FLEXIBILITY PROVISIONS
General: Install flexible couplings to facilitate installation of piping, connections to
equipment and pumping units, and to permit disassembly of valve, instrumentation
components in accordance with approved Shop Drawings.
Flexible Joints at Concrete Backfill or Encasement: Install within 18-inches from the
termination of any concrete backfill or encasement.
Flexible Joints at Concrete Structures:
Install 18-inches or less from the face of structure; joint may be flush with face.
Install a second flexible joint, whether shown or not:
Pipe Diameter 18-Inches and Smaller: Within 18-inches of the first flexible
joint.
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Pipe Diameter Larger Than 18-Inches: Within one pipe diameter of the first
flexible joint.
3.3DIELECTRIC FITTING APPLICATIONS
Dry Piping Systems: Connect piping of dissimilar metals with the following:
NPS2 and Smaller: Dielectric unions.
NPS2-1/2 to NPS12: Dielectric flanges or dielectric flange kits.
Wet Piping Systems: Connect piping of dissimilar metals with the following:
NPS2 and Smaller: Dielectric couplings.
NPS2-1/2 to NPS4: Dielectric nipples.
NPS2-1/2 to NPS8: Dielectric nipplesor dielectric flange kits.
NPS10 and NPS12: Dielectric flange kits.
3.4PIPING INSTALLATION
Install piping according to the following requirements and Division 40 Sections specifying
piping systems.
Drawing plans, schematics, and diagrams indicate general location and arrangement of
piping systems. Indicated locations and arrangements were used to size pipe and calculate
friction loss, expansion, pump sizing, and other design considerations. Install piping as
indicated unless deviations to layout are approved on the Coordination Drawings.
Install piping indicated to be exposed and piping in equipment rooms and service areas at
right angles or parallel to building walls. Diagonal runs are prohibited unless specifically
indicated otherwise.
Install piping to permit valve servicing.
Install piping at indicated slopes.
Install piping free of sags and bends.
Install fittings for changes in direction and branch connections.
Select system components with pressure rating equal to or greater than system operating
pressure.
Sleeves are not required for core-drilled holes.
Permanent sleeves are not requiredfor holes formed by removable PE sleeves.
Penetrations: Install sleeves for pipes passing through concrete and masonry walls and
concrete floor and roof slabs.
Cut sleeves to length for mounting flush with both surfaces.
Exception: Extend sleeves installed in floors of equipment areas or other wet
areas 2-inches above finished floor level.
Install sleeves in new walls and slabs as new walls and slabs are constructed.
Steel Pipe Sleeves: For pipes smaller than NPS6.
Steel Sheet Sleeves: For pipes NPS6 and larger, penetrating gypsum-board
partitions.
Watertight Penetrations;
Provide wall pipes with thrust collars. Wall rings with tapped flanges are not
allowed.
Non-Watertight Penetrations:
Pipe sleeves with seep ring or modular mechanical seal.
Sleeves are not required for core-drilled openings.
Existing Walls: Core-drilled openings and use modular mechanical seal.
Caulk all sleeves water and air tight. Seal annular space between pipe and sleeve with
fire stopping compound.
Verify final equipment locations for roughing-in.
Refer to equipment specifications in other Sections for roughing-in requirements.
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Isolation Valves: Provide piping systems with line size shutoff valves located at risers, at
main branch connections to mains for all equipment, and at other locations as indicated and
required.
Vent and Drain Valves:
Pipe 2-1/2 Inch Diameter and Larger: 3/4-inch vent, 1-inch drain, unless otherwise
shown.
Pipe 2-inch and Smaller: 1/2-inch vent. 3/4-inch drain, unless otherwiseshown.
Install vent and drain valves at low points (drains) and high point (vents) of piping
systems so that these systems can be entirely drained and vented. Provide line size
ball valves for all vents and drains.
Gravity drain systems beneath slabs shall be ductileiron, except for chemical drains, unless
shown specifically on Plans. Encase all piping beneath slabs.
Install cleanouts on sludge piping so that all runs between bends may be accessed and at
intervals not exceeding 250feet on straight runs.
All boltsand fasteners on buried or submerged fittings and valves shall be Type316
stainless steel.
Provide taps and connections for flushing, testing, and disinfecting pipeline systems.
Provide taps or weld-u-lets with stainless steel ball valves and piping at all high points in the
piping systems for addition of air valves.
3.5PIPING JOINT CONSTRUCTION
General:
Join pipe and fittings according to the following requirements and Division40Sections
specifying piping systems.
Ream ends of pipes and tubesand remove burrs. Bevel plain ends of steel pipe.
Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings
before assembly.
Threaded Joints: Thread pipe with tapered pipe threads according to ASMEB1.20.1. Cut
threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and
restore full ID. Join pipe fittings and valves as follows:
Apply appropriate tape or thread compound to external pipe threads unless dry seal
threading is specified.
Damaged Threads: Donot use pipe or pipe fittings with threads that are corroded or
damaged. Do not use pipe sections that have cracked or open welds.
Welded Joints: Construct joints according to AWSD10.12, using qualified processes and
welding operators according to Part1 "Quality Assurance" Article.
Push-on Joints:
Comply with the recommendations of the pipe manufacturer relative to gasket
installation and other jointing operations.
Prepare pipe ends by removing from bell and spigot ends all lumps, blisters, excess
coal-tar coatings, oil and grease, then wire brush and wipe clean and dry before
laying pipe.
Install ring gasket and, when seated, apply thin film of lubricant to inside surface of
gasket.
Set spigot, applying lubricant as necessary, aligning with bell and contacting gasket.
Pipe 6-inches and smaller may be driven with a bar lever on end of pipe.
For larger pipe, use only approved ratchet-type jacking tool to pull pipe "home."
Flanged Joints:
Prior to installation of bolts, accurately center and align flanged joints to prevent
mechanical prestressing of flanges, pipe and equipment. Align bolt holes to straddle
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the vertical, horizontal or north-south center line. Do not exceed 3/64-inch per footof
inclination of the flange face from true alignment.
Select appropriate gasket material, size, type, and thickness for service application.
Install gasket concentrically positioned.
Use bolts, nuts, and washers of the designated material for service conditions.
Tighten bots progressively to prevent unbalance stress. Draw bolts tight to ensure
proper seating of gaskets. Use suitable lubricants on bolt threads.
Mechanical Joints:
Assemble in accordance with manufacturer’s instructions. Remove all foreign matter
from pipe ends, gaskets, and fittings before installation.
Wash ends of pipe, gaskets, and fittings with soapy water before assembly.
If effective sealing is not obtained, disassemble joint and clean and reassemble. Over
tightening bolts to compensate for poor installation practice will not be permitted.
Mechanical joints shall be suitably restrained to prevent movement.
Mechanical Couplings, Rigid:
Install per manufacturer’s instructions. Pipe ends shall be clean and smooth.
Space between pipe ends shall be at least 1/4-inch, but not more than one inch.
Flexible Couplings and Flanged Coupling Adapters:
Install per Drawings and in accordance with manufacturer’s instructions at locations
to facilitate removal of equipment, valves, and other elements.
All flexible couplings and flanged couplings shall be restrained.
Grooved Joints: Assemble joints with grooved-end pipe coupling with coupling housing,
gasket, lubricant, and bolts according to coupling and fitting manufacturer's written
instructions.
Soldered Joints: Apply ASTMB813 water-flushable flux, unless otherwise indicated, to tube
end. Construct joints according to ASTMB828 or CDA's "Copper Tube Handbook," using
lead-free solder alloy (0.20 percent maximum lead content) complying with ASTMB32.
Brazed Joints: Construct joints according to AWS's "Brazing Handbook," "Pipe and Tube"
Chapter, using copper-phosphorus brazing filler metal complying with AWSA5.8.
Pressure-Sealed Joints: Assemble joints for plain-end copper tube and mechanicalpressure
seal fitting with proprietary crimping tool to according to fitting manufacturer's written
instructions.
Plastic Piping Solvent-Cemented Joints: Clean and dry joining surfaces. Join pipe and
fittings according to the following:
Comply with ASTMF402 for safe-handling practice of cleaners, primers, and solvent
cements.
CPVC Piping: Join according to ASTMD2846.
PVC Pressure Piping: Join schedule number ASTMD1785, PVC pipe and PVC socket
fittings according to ASTMD2672. Join other-than-schedule-number PVC pipe and
socket fittings according to ASTMD2855.
PVC Nonpressure Piping: Join according to ASTMD2855.
Plastic Pressure Piping Gasketed Joints: Join according to ASTMD3139.
Plastic Nonpressure Piping Gasketed Joints: Join according to ASTMD3212.
Plastic Piping Heat-Fusion Joints: Clean and dry joining surfaces by wiping with clean cloth
or paper towels. Join according to ASTMD2657.
Plain-End PE Pipe and Fittings: Use butt fusion.
Plain-End PE Pipe and Socket Fittings: Use socket fusion.
Bonded Joints: Prepare pipe ends and fittings, apply adhesive, and join according to pipe
manufacturer's written instructions.
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3.6VALVES AND VALVE BOXES
Prior to installing valves, remove foreign matter from within the valve. Inspect valves in the
open and closed position to verify that all parts are in satisfactorily working condition.
Install valves, setting valves plumb, with operators aligned as shown on the Drawings. For
buried valves, center valve boxes on valves. Carefullytamp earth around each valve box for
a minimum of four feet or to the trench face if less than four feet.
3.7SECURING AND SUPPORTING
Exposed Piping Systems:
Engineered Hanger and Support System: The CONTRACTOR provide an engineered
hanger and support system for the various piping systems in accordance with Section
40 05 07“Hangers and Supports for Process Piping;” as shown on the Drawings; and
as specified herein to maintain the line and grade and prevent the transfer of stress
to pumps, equipment and other related work.
This includes the design of multiple piping supports and trapeze hangers and
the selection of appropriate hangers and anchors to the structures, buildings,
and facilities. This design shall be accomplished by a professional engineer
license in the state where the Project is to be constructed.
Reaction Anchorage and Blocking: Install suitable reaction blocking, struts, anchors,
clamps, joint harness, or other adequate means for preventing movement of pipe
caused by unbalanced internal liquid pressure. Pressure can be expected at tees,
elbows, Y-branches, and other bends, which are installed in piping subjected to
internal hydrostatic heads in excess of 15-feet in exposed piping.
Buried Piping Systems:
Reaction Anchorage and Blocking: Install suitable reaction blocking, struts, anchors,
clamps, joint harness, or other adequate means for preventing movement of pipe
caused by unbalanced internal liquid pressure. Pressure can be expected at unlugged
tees, Y-branches and bends deflecting 11-1/4 degrees or more, which are installed in
piping subjected to internal hydrostatic heads in excess of 30-feet in buried piping.
Restrained Joints:
Unless otherwise indicated on the Drawings, the CONTRACTOR shall provide
restrained pipe joints and fittings in accordance with Part 1 Project
Requirements.
All fittings shall be restrained using restrained joint pipe and fittings for a
sufficient length to resist the internal hydrostatic pressures.
Restrained push-on pipe and fittings shall be capable of being deflectedafter
assembly.
The design for restrained joints, including the length necessary to resist the
design thrust and the approval of the fill material and compaction method, shall
be performed and sealed by a professional engineer license in the state where
the Project is to be constructed.
The above applies to unsaturated soil conditions. In locations where ground
water is encountered, the soil density shall be reduced to its buoyant weight for
all backfill below the water table and the coefficient of friction shall be reduced
to 0.25.
Bends and Appurtenances:
Provide restrained at all bends.
Horizontal changes in pipe direction may be accomplished without the
use of direction-changing fittings. Controlled horizontal longitudinal
bending using deflected jointsmay be used and shall not exceed 50
percent of the manufacturer’s written recommendations.
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Vertical changes in pipe direction may be accomplished without the use
of directional-changing fittings which require vertical thrust blocking
and/or joint restraint. Controlled vertical longitudinal bending shall be
accomplished using deflected joints, resulting in a circular pipe arc where
joints do not require restraint. Joint deflections shall not exceed 50
percent of the manufacturer’s written recommendations.
Valves, hydrants, and fittings shall be supported by a concrete block or
concrete cradle. The weight of these items shall not be supported by the
pipe.
Concrete Thrust Blocking:When specifiedon the Drawings or with written approval
from the ENGINEER,provide concrete thrust blocking between the fitting and solid,
undisturbed ground. Unless specifically shown on the Drawings, concrete thrust
blocking is not allowedat water or wastewater treatment plant sites.
In the event that adequate support against undisturbed ground cannot be obtained,
install metal harness anchorages consisting of steel rods or bolts across the joint and
securely anchored to the pipe and fittings, or other adequate anchorage facilities.
3.8CORROSION PROTECTION
Provide corrosion protection for all steel clamps, rods, bolts, and other metal accessories
used in reaction anchorages or joint harness where subject to submergence or contact with
earthor other fill material and not encased in concrete. Apply not less than two coats of
coal-tar mastic coating material to clean, dry metal surfaces. Allow first to dry prior to
application of second coat.
3.9PIPING CONNECTIONS
Make connections according to the following, unless otherwise indicated:
Install unions, in piping NPS2 and smaller, adjacent to each valve and at final
connection to each piece of equipment.
Install flanges, in piping NPS2-1/2 and larger, adjacent to flanged valves and at final
connection to each piece of equipment.
Install dielectric fittings at connections of dissimilar metal pipes.
Connections with Existing Piping:
Field verify all dimensions, sizes, configuration and related items on all existing piping
to which connections are to be made.
Connections between new work and existing piping shall utilized suitable fittings for
the conditions encountered.
Each connection with an existing pipe shall be made at a time under conditions which
will least interfere with service to the OWNER or to customers, and as authorized by
the OWNER. Provide notification48 hours in advance prior to making connections.
Pipe Connections:
Piping connections shall be of the type indicated on the Drawings or in the Piping
Scheduleprovided in the Drawings.
Field-welded joints will be permitted only when indicated on the Drawings and will
require approval of the ENGINEER.
Field-welded joints will only be permitted at locations where the interior coatings can
be repaired and inspected.
Additional flanged, compression sleeve or grooved end couplings may be added by
the CONTRACTORto facilitate fabrication, handling, transportation and field assembly
at no additional cost.
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3.10EQUIPMENT INSTALLATION
Install equipment level and plumb, unless otherwise indicated.
Install equipment to facilitate service, maintenance, and repair or replacement of
components. Connect equipment for ease of disconnecting, with minimum interference with
other installations. Extend grease fittings to an accessible location.
Install equipment to allow right of way to piping systems installed at required slope.
3.11PAINTING
Painting of piped systems, valves, specials, hangers and supports, equipment, and
components shall be as specified in the various sections and Section 09 91 00 “Painting and
Protective Coatings.”
Damage and Touchup: Repair marred and damaged factory-painted finishes with materials
and procedures to match original factory finish.
3.12IDENTIFICATION
Piping Systems: Install pipe and valve markers, includingarrows showing normal direction
of flowin Accordance with Section 10 90 00 “Identification, Stenciling, and Tagging.”
Plastic markers, with application systems. Install on insulation segment if required for
hot non-insulated piping.
Locate pipe markers on exposed piping according to the following:
Near each valve and control device.
Near each branch, excluding short takeoffs for equipment and terminal units.
Mark each pipe at branch if flow pattern is not obvious.
Near locations where pipes pass through walls or floors or enter inaccessible
enclosures.
At manholes and similar access points that permit view of concealed piping.
Near major equipment items and other points of origination and termination.
Buried Piping System Identification:
Buried water piping systems shall have marking tape installed approximately 12-
inches above the pipe.
Install detectable warning tape above non-metallic pipelines.
Equipment: Install engraved plastic-laminate sign or equipment marker on or near each
major item of equipment in accordance with Section 10 90 00 “Identification, Stenciling,
and Tagging” and the following:
Lettering Size: Minimum 1/4 inch high for name of unit if viewing distance is less
than 24 inches, 1/2 inch high for distances up to 72 inches, and proportionately larger
lettering for greater distances. Provide secondary lettering two-thirds to three-fourths
of size of principal lettering.
Text of Signs: Provide name of identified unit. Include text to distinguish among
multiple units, inform user of operational requirements, indicate safety and
emergency precautions, and warn of hazards and improper operations.
Adjusting: Relocate identifying devices that become visually blocked by work of this or
other Divisions.
Wiring: Identify system components, wiring, cabling, and terminals. Comply with
requirements for identification specified in Section 10 90 00 “Identification, Stenciling, and
Tagging”.
3.13CONCRETE BASES
Concrete Bases: Anchor equipment to concrete base according to equipment
manufacturer's written instructions and according to seismic codes at Project.
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Construct concrete bases of dimensions indicated, but not less than 4 inches larger in
both directions than supported unit.
Install dowel rods to connect concrete base to concrete floor. Unless otherwise
indicated, install dowel rods on 18-inch centers around the full perimeter of base.
Install epoxy-coated anchor bolts for supported equipment that extend through
concrete base, and anchor into structural concrete floor.
Place and secure anchorage devices. Use supported equipment manufacturer's
setting drawings, templates, diagrams, instructions, and directions furnished with
items to be embedded.
Install anchor bolts to elevations required for proper attachment to supported
equipment.
Install anchor bolts according to anchor-bolt manufacturer's written instructions.
Use 3000-psi, 28-day compressive-strength concrete and reinforcement as specified in
Section 03 30 00“Cast-in-Place Concrete."
3.14ERECTION OF METAL SUPPORTS AND ANCHORAGES
Refer to Section 40 05 07“Hangers and Supports for Process Piping” for information on the
installation ofthe engineeredhangers and supports for piping systems.
3.15CONNECTIONS TO EQUIPMENT FURNISHED BY OTHERS
Provide service connections to equipment furnished by others, utilizing equipment shop
drawings furnished for indicating type, number and location of connecting points. As part of
the work, field adjustments as to the type, number, and location may be required. This is
considered part of the Work.
Roughing-In: Extend service connections to various items of equipment. Temporarily
terminate at proper points as indicated on the shop drawings furnished or as directed.
Final Connections: Provide items, such as pipe, fittings, adapters, valves, insulation,
and other materials, required to connect equipment from the rough-in locations.
Valves: Provide cut-off valve for each service at rough-in locations, except drains.
3.16CLEANING OF PIPING SYSTEMS
Clean piping systems thoroughly. Purge pipe of construction debris and contamination
before placing the system in service. Provide temporarily connections required for cleaning,
purging and circulation.
Install temporary strainers in front of pumps, tanks, solenoid valves, control valves, and
other equipment where permanent strainers are not indicated. Keep these strainers in
service until the equipment has been tested, then remove either entire strainer or straining
element only. Fit strainers with line size blow off valve.
Circulate a chemical cleaner in chilled, heating and condensing water systems; and steam
and condensing piping systems to remove mill scale, grease, oil, and silt. Circulate for 48-
hours, flush system and replace with clean water. Dispose of chemical solution in
accordance with local ordinances. The type and quantity of cleaning chemicals shall be as
recommended by the supplier for the service.
3.17FIELD QUALITY CONTROL
Testing Agency: Engage a qualified testing agency to perform tests and inspections.
Tests and Inspections:
Lined carbon steel pipe and fittings shall be inspected by the CONTRACTOR after
installation to ensure linings are intact in accordance with the piping system section
and shall certify to that effect.
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Pipe 24-Inches and Smaller: Engage an inspection organization to video inspect
pipe and report findings.
Pressure test piping systems in accordance with Section 400105 “Field Testing of
Piping Systems.”
Additionalfield-testing shall be as described in the individual piping systems Sections
of Division 40.
The piping system component(s) will be considered defective if it does not pass tests and
inspections.
Prepare test and inspection reports.
3.18SUPPLEMENTS
Piping Schedule is provided inthe Drawings.
END OF SECTION
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SECTION40 05 07
HANGERS AND SUPPORTS FOR PIPING SYSTEMS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Work covered under this Section consists of providing hangers and supports for equipment
and piping systems.
Related Sections:
Section 05 50 00“Metal Fabrications” for materials for attaching hangers and
supports to structures and buildings.
1.3DEFINITIONSAND REFERENCES
Definition:
Wetted or Submerged: Submerged, less than one foot above liquid, below top of
channel wall, under cover or slab of channel or tank, or in other damp locations.
References:
American Welding Society (AWS):
D1.1 –Structural Welding Code-Steel
D1.2 -Structural Welding Code-Aluminum
D1.6 -Structural Welding Code-Stainless Steel
American Society of Mechanical Engineers:
B31.9-Standard Building Services Piping
Section IX, Boiler and Pressure Vessel Code: Welding and Brazing Qualifications
ASTM International (ASTM):
B 633 –Specification for Electrodeposited Coatings of Zinc on Iron and Steel
A 36-Standard Specifications for Carbon Structural Steel
A 123 –Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
A 183 –Specification for Carbon Steel Track Bolts and Nuts
A 525 –Specification for General Requirements for Steel Sheet, Zinc-Coated
(Galvanized) by the Hot-Dip Process.
A 653 –Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron
Alloy-Coated (Galvannealed) by the Hot-Dip Process.
A 780 –Practice for Repair of Damaged and Uncoated Areas of Hot-Dip
galvanized Coatings.
A 1011 –Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon,
Structural, high-Strength Low-Alloy, High-Strength Low-Alloy with Improved
Formability, and Ultra-High Strength
C 1107 –Specification for Packaged Dry Hydraulic Cement (Non-Shrink)
F 844 –Specification for Washers, Steel, Plain (Flat), Unhardened for General
Use Only
Manufacturers Standardization Society (MSS):
SP-58 Pipe Hangers and Supports-Materials, Design and Maintenance
SP-69 Pipe Hangers and Supports-Selection and Application
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SP-89 PipeHangers and Supports-Fabrication and Installation Practices
SP-127 Bracing for Piping Systems Seismic-Wind-Dynamic Design, Selection,
Application
NFPA (National Fire Protection Association):
NFPA 13 –Standard for the Installation of Sprinkler Systems
NFPA-14 -Standard for the Installation of Standpipes and Hose Systems
NFPA 70-National Electrical Code
1.4SUBMITTALS
Product Data:
Product data to include, but not be limited to materials, finishes, testing agency
approvals, load ratings, and dimensional information.
Provide installation instructions for each type of hanger and support.
Submit pipe hanger and support schedule showing manufacturer's Figure No., size,
location, and features for each required pipe hanger and support.
Shop Drawings: Provide for each type of hanger and support, indicating dimensions,
weights, required clearances, and methods of component assembly. Indicate all loads
exceeding 250 lbs imposed on building support systems and on structures.
Informational Submittals:
Welder certificates signed by Contractor certifying that welders comply with
requirements specified under the "Quality Assurance" Article.
Product certificates signed by manufacturer certifying that their product meet the
specified requirements.
Provide manufacturer’s warranty for all products indicated.
1.5QUALITY ASSURANCE
Welding:
Qualify welding processes and welding operators according to the following codes
depending on the material welded.
AWS D1.1 "Structural Welding Code--Steel."
AWS D1.2 "Structural Welding Code-Aluminum.”
AWS D1.6 "Structural Welding Code-Stainless Steel.”
Certify that each welder has satisfactorily passed AWS qualification tests for welding
processes involved and, if pertinent, has undergone recertification.
Qualify welding processes and welding operators according to ASME "Boiler and Pressure
Vessel Code," Section IX, "Welding and Brazing Qualifications."
NFPA Compliance: Comply with NFPA13 for hangers and supports used as components of
fire protection systems.
Listing and Labeling: Provide hangers and supports that are listed and labeled as defined in
NFPA70, Article100.
UL and FM Compliance: Hangers, supports, and components include listing and
labeling by UL and FM where used for fire protection piping systems.
Listing and Labeling Agency Qualifications: A “Nationally Recognized Testing
Laboratory” (NRTL) as defined in OSHA Regulation 1910.7.
Licensed Operators: Use operators that are licensed by powder-operated tool manufacturers
to operate their tools and fasteners.
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1.6SYSTEMDESCRIPTION
Engineered Hanger and Support System: The CONTRACTOR shall provide an engineered
hanger and support system for the various piping systems indicted on the Drawings. This
4
includes the design of multiple piping supports and trapeze hangers and the selection of
appropriate hangers and anchors to the structures, buildings, and facilities. This design shall
be accomplished by a professional engineer license in the state where the Project is to be
constructed.
Hanger and Support System: The CONTRACTOR shall provide a hanger and support system
for the various piping systems indicated on the Drawings. The number and type of hangers
and supports necessary for the project, including the types of inserts and size of rods
necessary to carry the installed weights shall be determined by the CONTRACTOR, based on
calculated loads to be supported.
Codes and Standards:
Regulatory Requirements: Comply with applicable plumbing codes pertaining to
product materials and installation of the hanger and support system.
NFPA Compliance: Hanger and support system shall comply with NFPA -13 when used
as a component of a fire protection system and NFPA-14 when used as a component
of a standpipe system.
UL and FM Compliance: Hanger and support system components shall be listed and
labeled by UL and FM when used for fire protection systems.
National Recognized Testing Laboratory and NEMA Compliance (NRTL): Instead of UL
and FN compliance, the hanger and support system components shall be listed and
labeled by a NTRL where used for fire protection systems. The term “NTRL” shall be
as defined in OSHA Regulation 1910.7.
Duct Hangers: SMACNA Duct Manuals.
MSS Standard Compliance: Provide hanger and support system components of which
materials, design, and manufacture comply with MSS SP-69.
Piping shall be installed in a manner that piping is not strained during installation.
Pipe shall not be installed in a manner that requires force to align pipe runs, or that
4
requires force to install piping into hangers.
Hangers and supports shall be capable of vertical adjustment after the piping has
been installed. Hangers that do not allow for such adjustment shall have turnbuckles
installed in the hanging rod.
Where pipe is noted to be insulated, the pipe hanger shall not penetrate the pipe
covering. Pipe hangers shall be on the outside of the insulation. Provide protection
saddles or insulation inserts to prevent damage to insulation.
Piping which runs at an elevation exceeding 8’-0” from the structure above, and as
indicated on the plans may be supported from wall-mounted brackets attached to
concrete wall surfaces.
Design Requirements:
General:
The configuration and layout of yard and station piping systems are shown in
the Drawings.
In certain locations, pipe supports, anchors, and expansion joints have been
indicated on the drawings, but no attempt has been made to indicate every
pipe support, anchor, and expansion joint.
It shall be the CONTRACTOR'S responsibility to provide a complete system of
pipe supports, to provide expansion joints, and to provide restraints and anchor
all piping, in accordance with the requirements set forth herein.
Additional pipe supports may be required adjacent to expansion joints,
couplings, flanged connections, or valves.
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Piping Smaller than 30-inches: Supports are shown only where specific types
and locations are required; provide additional pipe, valve, and equipment
supports as required.
Piping 30-inches and Larger: Support systems have been designed for piping
and shall be placed at the designated locations as shownon the Drawings.
Piping 3-inches and Smaller: It is the CONTRACTOR’S responsibility to provide
a complete support system even if no supports are indicated on the Drawings.
Comply with the requirements of MSS SP-58, MSS SP-69, and MSS SP-89.
Piping Support Systems:
Support Load: Dead loads imposed by weight of pipes filled with water, except
air and gas pipes, plus insulation.
Safety Factor: Minimum of 5.
Maximum Support Spacing and Minimum Rod Size:
Steel or Ductile Iron Piping:
Table 1
Steel or Ductile Iron Pipe
Maximum Minimum Rod Size
Pipe SizeSupport/Hanger SpacingSingle Rod Hangers
1-inch and smaller6 feet1/4-inch
1-1/2-inch thru
8 feet1/4-inch
2-1/2-inch
3-inch & 4-inch10 feet3/8-inch
6-inch12 feet3/8-inch
8-inch12 feet1/2-inch
10-inch & 12-inch14 feet5/8-inch
14-inch16 feet3/4-inch
16-inch & 18-inch16 feet7/8-inch
20-inch18 feet1-inch
24-inch18 feet1-1/4-inch
30-inch and largerAs shown on DrawingsAs shown on Drawings
Copper Piping:
Maximum Support Spacing: Two (2) feet less per size than listed
for steel, with 1-inch and smaller pipe supported every five (5)
feet.
Minimum Hanger Rod Size: Same as listed for steel pipe.
Plastic and Fiberglass Piping:
Maximum Support Spacing: As recommended by manufacturer for
flow and temperature in pipe.
Minimum Rod Sizing: Same as listed for steel pipe.
Provide supports with width as required by pipe manufacturer and
shields as required to protect pipe in accordance with
manufacturer’s requirements.
Stainless Steel Piping:
Table 2
Stainless Steel Pipe
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Maximum Minimum Rod Size
Pipe SizeSupport/Hanger spacingSingle Rod Hangers
1-inch thru 4-inch8 feet1/4-inch
6-inch8 feet3/8-inch
8-inch & 10-inch10 feet1/2-inch
12-inch10 feet1/2-inch
14-inch & 16-inch12 feet5/8-inch
18-inch & 20-inch14 feet¾-inch
24-inch14 feet7/8-inch
Framing Support Systems:
Beams: Size such that beam stress does not exceed 25,000 psi and maximum
deflection does not exceed 1/240 of span.
Column Members: Size in accordance with manufacturer’s recommended
method.
Support Loads: Calculate using weight of pipes filled with water.
Maximum Spans:
Steel and Ductile Iron Pipe, 3-Inch Diameter and Larger: 10-foot centers,
unless otherwise shown.
Other Pipelines and Special Situations: May require supplementary
hangers and supports.
Electrical Conduit Support: Include in design of framing support systems.
Anchoring Devices: Design, size, and pace support devices, including anchor bolts,
inserts, and other devices used to anchor support, to withstand shear and pullout
loads imposed by loading and spacing on each particular support.
Vertical Sway Bracing: 10-foot maximum centers, or as shown.
Existing Support Systems: use existing support systems to support new piping only if
CONTRACTOR can show that they are adequate for the additional loads, or if they are
strengthened to support the additional load.
1.7PRODUCT DELIVERY, STORAGE AND HANDLING
Comply with the manufacturer's recommendationsand Section 016000 “Product
Requirements.”
PRODUCTS
2.1MANUFACTURED UNITS
General:
When specified items are not available, fabricate pipe supports of correct material and
to general configuration indicated incatalogs.
Special supports and hangers details will be requiredfor cases where standard
catalog supports are inapplicable.
Materials:Unless otherwise shown on the Drawings, fabricate supports using the
following materials:
Wetted and Submerged: Type 316 Stainless Steel.
Atmospheric Exposed: Hot-dipped galvanize after fabrication, coat in
accordance with Section 099100 “Paintingand Protective Coatings.”
Hardware: Type 316 Stainless Steel.
Hangers, Supports, and Components:
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Selection and application of pipe hangers and supports for all service temperatures
shall be in accordance with MSS SP-69.
Requirements for material, design and manufacture of standard types of hanger and
support system components shall be in accordance with MSS SP-58.
Requirements for the fabrication and installation of the hanger and support system
shall be in accordance with MSS SP-89.
Requirements relating to the design, selection, and applications of bracing for piping
systems subject to seismic-wind-dynamic loading shall be in accordance with MSS SP-
127.
Components include galvanized coatings where installed for piping and equipment
that will not have a field-applied finish.
Pipe attachments shall include a nonmetallic coating for electrolytic protection where
attachments are in direct contact with copper pipe and tubing.
Products:
Available Products: Subject to compliance with requirements, products that may be
incorporated into the Work include, but are not limited to, the following:
ANVIL International, Inc.
Cooper B-Line, Inc.
National Pipe Hanger Corporation
Piping Technology & Products, Inc.
2.2HANGERS
Adjustable Clevis Hanger: MSS SP-58, Type 1.
Adjustable Swivel Ring for Non-Insulated Pipe: MSS Type 7.
Hinged Split-Ring Pipe Clamp: MSS SP-58, Type 6 or 12.
Yoke and Roller Hanger: MSS Type 41 and 43.
U-Bolts: MSS Type 24.
Straps: MSSType 26.
AnchorRods, Clevises, Nuts, Sockets, and Turnbuckles: In accordance with MSS SP-58.
Attachments:
I-Beam Clamp: Concentric loading type, MSS SP-58, Type 21, 28, 29, or 30, which
engage both sides of flange.
Concrete Insert: MSS SP-58, Type 18, continuous channel insert with load rating not
less than that of hanger rod it supports.
2.3PIPESUPPORTS
Pedestal Type: Schedule 40 pipe stanchion, saddle, and anchoring flange.
Nonadjustable Saddle: MSS SP-58, Type 37 with U-bolt.
Adjustable Saddle: MSS SP-58, Type 38 without clamp.
Pipe Stanchion: Anvil Figure 62 and 63 for support of steel pipe elbows, horizontal pipe, and
for use with pipe saddles.
2.4ROLLERS AND ROLLER SUPPORTS
Roller with Adjustable Support Stand:
Designed for pipe support where longitudinal movement and vertical adjustment is
required.
Non-metallic roller with stainless steel stand and hardware.
Complies with MSS SP-69 and SP-58, Type 46.
Roller with Non-Adjustable Support Stand:
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Designed for supporting pipe with longitudinal movement.
Non-metallic roller with stainless steel chair, stand and hardware.
Complies with MSS SP-69 and SP-58, Type 44.
Roller with Ceiling Suspended Supports:
Designed for suspending pipe where longitudinal movement and vertical adjustment is
required.
Steel with cast iron roller, standard finish.
Complies with MSS SP-69 and SP-58, Type 43 or Type 41.
2.5WALL SUPPORTS
Horizontal Pipe:
1/4-Inch Thru 4-Inches: Offset or straight J-hook.
4-Inches and Greater: Welded steel bracket MSS Type 31, 32, or 33 and wrought
steel clamp. Provide adjustable steel yoke and cast iron roll MSS Type 44 for hot pipe
0
200F and over and for sizes 6-inches and greater.
One-Hole Clamp: Anvil; Figure 126.
Channel Type: Unistrut, Anvil, Cooper B-Line.
2.6PIPE CLAMPS
Riser Clamp: MSS SP-58, Type 4.
Flexibility in hanger assembly required due to horizontal movement, use pipe clamps with
weldless eye nuts: MSS SP-58, Type 4, with Type 17. For insulated lines use double bolted
pipe clamps: MSS SP-58, Type 3, with Type 17.
Offset Pipe Clamp: Galvanized carbon steel clamp for use is supporting piping away from
floor or wall; Anvil Figure 103 or equivalent.
Extension Pipe or Riser Clamp: Galvanized carbon steel riser clamp for support of vertical
piping complying with MSS SP-69 and MSS-58, Type 8 and Type 42. Type 42 is designed
also to be supported by hanger rods.
2.7MULTIPLE OR TRAPEZE HANGERS
Trapeze hangers constructed from 12 gauge roll formed ASTM A1011 SS Gr. 33 structural
steel channel, 1-5/8-inch x 1-5/8-inch minimum.
Mount pipes to trapeze with two piece pipe straps sized for outside diameter of pipe.Pipes
subject to axial movement:
Use strut mounted roller supports; use pipe protection shield or saddles on FRPand
insulated lines.
Use strut mounted pipe guide as required.
2.8CHANNEL TYPE SUPPORT SYSTEMS
Steel Construction:
Channel: Pre-galvanized in accordance with ASTM A525, Class G90, or hot-dip after
fabrication.
Hardware:Type 316stainless steel.
Channel Size:
Single Channel:14-gauge, 1-5/8” by 1-5/8”.
Double Channel: 14-gauge, 3-1/4” by 1-5/8”.
Manufacturer: Unistrut Series P1000 or equivalent.
Members and Connections: MFMA-2, factory-fabricated components for field
assembly. Design for all loads with Safety Factor of 5.
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Pipe and Tubing Clamps: Unistrut “Cush-A-Clamp” Omega Series or U-Bolt Series,
stainless steel construction with thermoplastic elastomer cushion or equivalent.
Fiberglass Construction:
Channel: Polyester and vinylesterreinforce with multiple strands of glass filament, UV
resistant surfacing veils channels.
Single Channel:Heavy duty 1-5/8’” by 1-5/8”; Unistrut Series F20V-2000.
Double Channel: Heavy duty 3-1/4” by 1-5/8”; Unistrut Series F20V-2100.
Seal all cut ends with a clear sealer and provide end caps on exposed ends after
assembly.
Hardware: Fiberglass or stainless steel.
Available Manufactures:
Anvil; Power-Strut Line
Cooper B-Line
National Pipe Hangers Corporation
Unistrut Corporation
2.9ACCESSORIES
Protection Shields:MSS Type 40; galvanized steel or stainless steel, 180 degrees arc,
minimum 12-inches long, to prevent crushing insulation.
Protection Saddles: MSS Type 39; fill interior with segments of insulation matching adjoining
insulation.
Thermal Shields:
Provide 100-psi minimum compressive strength, waterproof, asbestos free calcium
silicate, encased with a sheet metal enclosure. Insert and shield shall cover the entire
circumference or the bottom half circumference of the pipe, with length
recommended by the manufacturer for pipe size and thickness of insulation.
Cold Piping: Calcium silicate shall extend beyond the sheet metal shield allowing
overlap of vapor barrier.
Piping, 4-inches and larger,supported on trapeze or pipe rollers, provide double
thickness shields.
Piping, 12-inches and greater,provide 600 psi calcium silicate structural insert.
Vibration Isolation and Supports:
For refrigeration, air conditionings, hydraulic, pneumatic, and other vibrating system
applications, usea clamp that has a vibration dampening inserts and a nylon inserted
locknut. For copper and steel tubing use Cooper B-Line BVT series VibraClamps, for
pipe sizes use BVP series, or equivalent.
For larger tubing or piping subjected to vibration, use neoprene or spring hangers as
required.For spring hangers use Mason or equal.
For base mounted equipment use vibration pads, molded neoprene mounts, or spring
mounts as required.
Vibration isolation products as manufactured by Cooper B-Line, VibraTrol systems, or
equivalent.
Intermediate Pipe Guides:
Piping, 6-inches and smaller:
Type: Pipe clamp with oversized pipe sleeve to provide minimum 1/8-inch
clearance.
Piping, 8-inches and larger:
Type: Specially formed U-bolts with double nuts to provide 1/4-inch minimum
clearance around pipe.
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U-Bolt Stock Size:
8-inch Pipe: 5/8-inch
10-inch Pipe: 3/4-inch
12-inch through 16-inch Pipe: 7/8-inch
18-inch through 30-inch Pipe: 1-inch
Pipe Alignment Guides:
Piping 8-inches and Smaller: Spider of sleeve type.
Piping 10-inches and Larger: Roller type.
Pipe Anchors:
Type: Anchor chair with U-bolt.
Hangers shall be threaded at either end or continuous threaded rods of circular cross
section. Use adjusting locknuts at upper attachments and hangers. No wire, chain, or
perforated straps are allowed.
2.10MISCELLANEOUS MATERIALS
Hanger Support Anchors: Comply with the requirements of Section 05 05 23“Metal
Fastenings and Anchor Bolts” for cast-in-place anchors, concrete and masonry drilled
anchors, and material of construction for anchors based on the environment.
Insert-type attachments with pull-out and shear capacities appropriate for supported
loads and building materials where used. Fasteners for fire protection systems
include UL listing and FM approval.
Powder actuated fasteners and other types of bolts and fasteners not specified herein shall
not be used unless approved by ENGINEER.
Powder-actuated-type, drive-pin attachments with pull-out and shear capacities
appropriate for supported loads and building materials where used. Fasteners for fire
protection systems include UL listing and FM approval.
Structural Steel: ASTMA36/A36M, steel plates, shapes, and bars, black and galvanized.
Bolts and Nuts: ASMEB18.10 or ASTMA183, steel, hex-head, track bolts and nuts.
Washers: ASTMF844, steel, plain, flat washers.
Grout: ASTMC1107, Grade B, nonshrink and nonmetallic;
Characteristics include post-hardening, volume-adjusting, dry, hydraulic-cement-type
grout that is nonstaining, noncorrosive, nongaseous and is recommended for both
interior and exterior applications.
Design Mix: 5000-psi, 28-day compressive strength.
Water: Potable.
Packaging: Premixed and factory-packaged.
EXECUTION
3.1PREPARATION
Examine areas and conditions under which the hanger and support system will be installed.
Do not proceed with work until satisfactorily conditions have been corrected in manner
acceptable to installer.
Proceed with installation of the hanger and support system only after required structural
work has been completed in areas where work is to be installed. Correct inadequacies
including, but not limited to. Proper placement of inserts, anchors, and other structural
attachments. Review Drawings to obtain structural support limitations.
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3.2HANGER AND SUPPORT INSTALLATION
General: Comply with MSSSP-69 and SP-89. Install hangers, supports, clamps, and
attachments as required to properly support piping from building structure.
Channel Support Installation: Arrange for grouping of parallel runs of horizontal piping
supported together on field-fabricated, heavy-duty trapeze hangers where possible.
Field assemble and install according to manufacturer’s instructions.
Heavy-Duty Steel Trapezes: Arrange for grouping of parallel runs of horizontal piping and
support together on field-fabricate heavy-duty trapezes.
Pipes of Various Sizes: Support together and space trapezes for smallest pipe size or
install support intermediate supports for smaller diameter pipes as specified above for
individual pipe hangers.
Field-fabricate from ASTM A36 steel shapes selected for loads being supported.
Weld steel according to AWS D-1.1.
Install building attachments within concrete or to structural steel. Space attachments within
maximum piping span length indicated in MSS SP-69. Install additional attachments at
concentrated loads, including valves, flanges, guides, strainers, expansion joints, and at
changes in direction of piping. Install concrete inserts before concrete is placed; fasten
insert to forms. Install reinforcing bars through openings at top of inserts.
Install powder-actuated drive-pin fasteners in concrete after concrete is placed and
completely cured. Use operators that are licensed by powder-actuated tool manufacturer.
Install fasteners according to powder-actuated tool manufacturer's operating manual. Do
not use in lightweight concrete slabs or in concrete slabs less than 4 inches thick.
Install mechanical-anchor fasteners in concrete after concrete is placed and completely
cured. Install according to fastener manufacturer's written instructions. Do not use in
lightweight concrete slabs or in concrete slabs less than 4 inches thick.
Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers,
and other accessories.
Support fire protection systems piping independent of other piping.
Install hangers and supports to allow controlled movement of piping systems, permit
freedom of movement between pipe anchors, and facilitate action of expansion joints,
expansion loops, expansion bends, and similar units.
Load Distribution: Install hangers and supports so that piping live and dead loading and
stresses from movement will not be transmitted to connected equipment.
Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and so that
maximum pipe deflections allowed by ASMEB31.9 "Building Services Piping" is not
exceeded.Insulated Piping: Comply with the following installation requirements.
Clamps: Attach clamps, including spacers (if any), to piping with clamps projecting
through insulation; do not exceed pipe stresses allowed by ASMEB31.9.
Saddles: Install protection saddles MSS Type 39 where insulation without vapor
barrier is indicated. Fill interior voids with segments of insulation that match
adjoining pipe insulation.
Shields: Install MSS Type 40, protective shields on cold piping with vapor barrier.
Shields span an arc of 180 degrees and have dimensions in inches not less than the
following:
Table 3
Shield Length and Thickness
NPSShield LengthShield Thickness
(Inches)(Inches)(Inches)
1/4 to 3-1/2120.048
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4120.060
5 and 6180.060
8 to 14240.075
16 to 24240.105
Pipes 8 Inches (200 mm) and Larger: Include wood inserts.
Insert Material: Length at least as long as the protective shield.
Thermal-Hanger Shields: Install with insulation of same thickness as piping.
Piping Support General Applications:
Support piping connections to equipment by pipe support and not by the equipment.
Support large or heavy valves, fittings, and appurtenances independently of
connected piping.
Do not support one pipe from another.
Support pipe at changes in direction or in elevation, adjacent to flexible joints and
couplings, and where shown.
Do not install pipe supports and hangers in equipment access areas or bridge crane
runs.
Brace hanging pipes against horizontal movement by both longitudinal and lateral
sway bracing.
Install pipe anchors where required to withstand expansion thrust loads and to direct
and control thermal expansion.
Repair mounting surfaces to original condition after attachments are made.
Standard Pipe Supports:
Horizontal Suspended Piping:
Single Pipes: Adjustable swivel-ring, split-ring, or clevis hangers.
Grouped Pipes: Trapeze hanger systems.
Furnished galvanized steel protection shield and oversized hangers for all
insulated pipes.
Furnish precut sections of rigid insulation with vapor barrier at hangers for all
insulated pipe.
Horizontal Piping Supported from Walls:
Single Pipes: Wall brackets or wall clips attached to wall with anchors. Clips
attached to wall mounted framing also acceptable.
Stacked Piping:
Wall mounted framing system and clips acceptable for piping smaller
than 3-inch nominal diameter.
Piping clamps which resist axial movement of pipe through support not
acceptable.
Wall mounted piping clips not acceptable for insulated piping.
Horizontal Piping Supported From Floors:
Stanchion Type:
Pedestal type; adjustable with stanchion, saddle, and anchoring flange.
Use yoked saddles for piping whose centerline elevation is 18-inches or
greater above the floor and for all exterior installations.
Provide neoprene waffle isolation pad under anchoring flanges, adjacent
to equipment or where otherwise required to provide vibration isolation.
Floor Mounted Channel Supports:
Use for piping smaller than 3-inch nominal diameter running along floors
and in trenches at piping elevations lower than can be accommodated
using pedestal pipe supports.
Attach channel framing to floors with anchor bolts.
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Attach pipe to channel framing with clips or pipe clamps.
Concrete Cradles: Use for piping larger than 3-inch nominal diameter along
floor and in trenches at piping elevations lower than can be accommodated
using stanchion type.
Vertical Pipe: Support with wall brackets and base elbow or riser clamps on floor
penetrations.
Standard Attachments:
To Concrete Ceilings: Concrete inserts.
To Steel beams: I-beam clamps or welded attachments.
To Wooden Beams: Lag screws and angle clips to members with anchor bolts.
To Concrete Walls: Concrete inserts or brackets or clip angles with anchor
bolts.
Existing Walls and Ceilings: Install as specified unless otherwise shown.
Intermediate and Pipe Alignment Guides:
Provide pipe alignment guides (or pipe supports that accomplishes the same function)
at all expansion joints and loops.
Guide piping on each side of an expansion joint or loop at four to fourteen pipe
diameters distance from each joint or loop.
Install intermediate guides on metal framing support systems not carrying a pipe
anchor or alignment guide.
Accessories:
Insulation Shield: Install on insulated non-steel piping. Oversized rollers and supports.
Welding Insulated Saddle: Install on insulated steel pipe. Oversized rollers and
supports.
Vibration Isolation Pad: Install under base flange of pedestal type pipe supports
adjacent to equipment, and where required to isolate vibration.
Dielectric Barrier:
Install between carbon steel members and copper or stainless steel pipe.
Install between stainless steel supports and nonstainless steel ferrous metal
piping.
Electrical isolation: Install 1/4-inch by 3-inch neoprene rubber wrap between
submerged metal pipe and oversized clamps.
Piping and ductwork supports are to be independent supports and directly supported from
building or structure. Combining supports from more than one trade is not permitted.
3.3EQUIPMENT SUPPORTS
Fabricate structural steel stands to suspend equipment from structure above or support
equipment above floor.
Grouting: Place grout under supports for equipment, and make a smooth bearing surface.
3.4METAL FABRICATION
Cut, drill, and fit miscellaneous metal fabrications for pipe and equipment supports.
Fit exposed connections together to form hairline joints. Field-weld connections that cannot
be shop-welded because of shipping size limitations.
Field Welding: Comply with AWSD1.1 procedures for manual shielded metal-arc welding,
appearance and quality of welds, methods used in correcting welding work, and the
following:
Use materials and methods that minimize distortion and develop strength and
corrosion resistance of base metals.
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Obtain fusion without undercut or overlap.
Remove welding flux immediately.
Finish welds at exposed connections so that no roughness shows after finishing, and
so that contours of welded surfaces match adjacent contours.
3.5ADJUSTING
Hanger Adjustment: Adjust hangers to distribute loads equally on attachments and to
achieve indicated slope of pipe.
3.6PAINTING
Touching Up: Cleaning and touchup painting of field welds, bolted connections, and abraded
areas of shop paint on miscellaneous metal is specified in Section099100 “Paintingand
Protective Coatings.”
Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply
galvanizing-repair paint to comply with ASTMA780.
3.7VIBRATION
Vibration of the piping system during operation is not acceptable.
CONTRACTOR shall provide additional lateral supports as required to eliminate piping
vibration at no addition cost to OWNER.
END OF SECTION
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SECTION 40 05 23
STAINLESS STEEL PROCESS PIPE AND TUBING
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section Includes:
Installation and testing stainless steel pipe and fittings, 1/2-inch through 42inches.
Testing and disinfection, as applicable, of stainless steel piping systems.
Related Work:
Refer to Division 40Section 40 05 05“Piping Systems,Basic Materials and Methods”
for information regarding submittals; coordination; material delivery, handling, and
storage; projection conditions; design requirements; other materials; installation of
piping systems; field testing; and related work.
This Section contains material requirements for pipe, fittings, specials, and
appurtenances for the various miscellaneous piping systems, as well as Part 1–
General and Part 3–Execution; additional requirements not specified in the above
referenced Section.
1.3REFERENCESAND DEFINITIONS:
References:
ASTM International, Inc. (ASTM):
A182 –Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged
Fittings, and Valves and Parts for High-Temperature Service
A194 –Specification for Carbon and Ally Steel Nuts for Bolts for High Pressure
or High Temperature Service, or Both
A240 –Specification for Chromium and Chromium-Nickel Stainless Steel Plate,
Sheet, and Strip for Pressure Vessels and for General Applications.
A312 –Specification for Seamless, Welded, and Heavily Cold Worked Austenitic
Stainless Steel Pipes
A320 –Specification for Alloy-Steel and Stainless Steel Bolting Materials for
Low-Temperature Service
A409 –Specification for Welded Large Diameter Austenitic Steel Pipe for
Corrosive or High-Temperature Service
A774 –Specification for As-Welded Wrought Austenitic Stainless Steel Fitting
for General Corrosive Service at Low and Moderate Temperatures
A778 –Specification for Welded, Unannealed Austenitic Stainless Steel Tubular
Products
F593 –Specification for Stainless Steel Bolts, Hex Cap Screws and Studs
F594 –Specification for Stainless Steel Nuts
American Water Works Association (AWWA):
C207 –Standard for Steel Pipe Flange for Waterworks Service. 4 In. Through
144 In.
C208 –Standard for Dimensions for Fabricated Steel Water Pipe Fittings
C220 –Standard for Stainless Steel Pipe, 4 In. and Larger
M-11 Steel Pipe-A Guide for Design and Installation
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Manufacturers Standardization Society (MSS):
SP-43 Wrought Stainless Steel Butt-Welding Fittings
1.4ADMINISTRATIVE REQUIREMENTS –NOT USED
1.5SUBMITTALS
Provide submittals in accordance with Section 01 33 00“SubmittalProcedures” and
Section 40 05 05 “Piping Systems, Basic Materialsand Methods.”
1.6QUALITY ASSURANCE
Requirements for Welding Operations:
Welding Procedures: Qualified under Se. IX, Part A, of the ASME Boiler and Pressure
Vessel Welding Code or under AWS B2.1.
Comply with AWWA C220.
1.7DELIVERY, STORAGE AND HANDLING –NOT USED
1.8SITE CONDITIONS –NOT USED
PRODUCTS
2.1MATERIALS
Pipe:
3-Inch and Smaller: Schedule 40 unless otherwise indicated in Pipe Schedule, ASTM
A312, Type 304L or 316L per Drawings, seamless, pickled and passivated.
4-Inches and Larger: Schedule 10 minimum as shown in Drawings, AWWA C220,
Type 304L or 316L per Pipe Schedule, fabricated from stainless steel stock ASTM
A312, ASTM A240, ASTM A409, or ASTM A778, pickled and passivated.
Piping shown as Duplex Stainless Steel on the Drawings shall be Type 2205 (UNS No.
S31803), pickled and passivated, and fabricated from stainless steel stock with the
following composition:
Carbon: 0.03%
Chromium: 21.0 –23.0%
Nickel: 4.5 –6.5%
Molybdenum: 3.0 –3.5%
Nitrogen: 0.08 –0.20%
Manganese: 2.00%
Pitting Resistance Equivalent Number (PREN): 33 –35
Joints:
3-Inch and Smaller: Welded joint with flanged end connections at valves and
equipment as required or as shownon Drawings.
High Pressure Air Service:
Buried: Welded joint with at least one Swagelok connection along each
straight run of pipe.
Above ground: Swagelok
4-Inches and Larger:
Buried: Butt-weld joints with at least one flexible connection along each
straight run of pipe.
Above ground: Pipe shall be factory fabricated in as large as possible. Factory
connections may be flanged or welded. All field connections shall be flanged
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end, and connections at valves and equipment shall be flanged.Provide 316 SS
Victaulic connections where shown on the drawings.
5
Fittings:
3-Inch and Smaller: Threaded forged, 1000 CWP, ASTM A182, Grade F316 unless
indicated otherwise on Pipe Schedule.
4-Inches and Larger: Butt-welded, ASTM A774, Grade 316, conforming to MSS SP-43,
“as-welded” grade, pickled and passivated; wall thickness to match adjoining pipe;
short radius, smooth formed (up to 24-inches) elbows, unless otherwise shown.
Short radius is defined as the radius on the bend equals the diameter of the fitting.
Dimensions shall conform to AWWA C208.
Piping called out as Duplex Stainless Steel on the Drawings shall have Type 2205
fittings meeting the requirements of Paragraph 2.1.A of this Section.
Branch Connections:
3-Inch and Smaller: Tee or reducing tee in conformance with fittings above.
4 Inches and Larger: Butt-welded tee or reducing tee in accordance with fittings
above. Saddling/coping of branch connection not permitted. Fabricated fittings are
acceptable. Refer to Item 2.1.J.
Flanges:
All Sizes: Flanges shall be Type 316L slip-on plate type conforming to ASTM A240 and
AWWA C207.
CONTRACTOR shall coordinate equipment to pipe connections.
Butt Weld Stub Ends: MS SP-43, Type “A”, Schedule to match pipe. Follower flanges
shall be Type 316L.
Piping called out as Duplex Stainless Steel on the Drawings shall have Type 2205
flanges meeting the requirements of Paragraph 2.1.A of this Section.
Unions, 3-Inch and Smaller, Threaded Forged: ASTM A312, 2,000 pound or 3,000 WOG,
integral ground seats, AAR design meeting requirements of ANSI B16.11, bore to match
pipe.
Bolting: Type 316 stainless steel, ASTM A320, Grade B8M hex head bolts, and ASTMA194,
Grade 8M, washers. All nuts shall be hex head style, stainless steel construction.
Piping called out as Duplex Stainless Steel on the Drawings shall have Type 2205
bolts meeting the requirements of Paragraph 2.1.A of this Section.
Gaskets:
Flanged, Water Service: 1/8-inch thick, unless otherwise specified, red rubber (SBR),
Shore A hardness 80, rated to 220F, conforming to ANSI B16.21, AWWA C208, and
ASTM D1330, Grades 1 and 2.
Flanged, Compressed air Service: 1/8-inch thick, unless otherwise specified,
homogeneous black rubber (EDPM), Shore A hardness 60, rated to 300F, conforming
to ANSI B16.21 and ASTM D1330 Steam Grade.
Blind flanges shall be gasketed covering the entire face with the gasket cemented to
the blind flange.
Expansion Joints: Expansion joints used on the low pressure air piping serving the Aeration
Basins shall bethe Victaulic 489DX type expansion coupling for piping 10-inch and smaller
and Victaulic 77S type expansion coupling for piping larger than 10-inch.
Thread Lubricant: Teflon tape or Teflon pipe lubricant.
Shop Fabricated Pipe and Fittings: Following shop fabrication, all stainless steel pipe and
fittings shall be pickled and passivated by immersion.
Markings: Pipe, fittings, and fabrications shall be properly marked with type, size, gauge,
and heat numbers.
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EXECUTION
3.1INSTALLER
Contractor
Comply with the requirements of Section 40 05 05 “Piping System, Basic Materials
and Methods” for the installation, cleaning, testing, coating and identification.
Do not perform any welding, cutting, or grooving of stainless steel piping in the field
unless specifically called for on the drawings or authorized in writing by the
ENGINEER.
3.2EXAMINATION –NOT USED
3.3PREPARATION –NOT USED
3.4INSTALLATION
CONTRACTOR shall comply with the installation requirements of Section 40 05 05 “Piping
System, Basic Materialsand Methods”.
3.5FIELD/SITE QUALITY CONTROL
Field Testing:
Comply with the requirements of Section 017525 “Equipment Testing and Startup”
Low pressure air piping systems shall be tested to 15 psi above operating
pressure unless otherwise indicated in the Pipe Schedule.
High pressure air piping systems shall be tested to 1.5 times the operating
pressure unless otherwise indicated in the Drawings.
3.6SYSTEM STARTUP –NOT USED
3.7CLOSEOUT ACTIVITIES –NOT USED
END OF SECTION
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SECTION 40 05 24
STEEL PIPE
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section Includes:
Fabricated, lined and coated steel pipe, sizes 6-inch through 144-inches.
Related Work:
Refer to Section 40 05 05“Piping System,Basic Materials and Methods” for
information regarding submittals; coordination; material delivery, handling, and
storage; projection conditions; design requirements; other materials; installation of
piping systems; field testing; and related work.
This Section contains material requirements for pipe, fittings, specials, and
appurtenances for the steel piping systems, as well as Part 1-General and Part 3-
Execution additional requirements not specified in the above referenced Section.
1.3REFERENCES
American National Standards Institute (ANSI):
B16.1 –Cast Iron Pipe Flanges, Class 25, 125, 250, and 800
B16.3 –Malleable Iron Threaded Fittings: Classes 150 and 300
B16.5 –Pipe Flanges and Flanged Fittings: NPS 1/2 through 24
B16.9 –Factory-Made Wrought Steel Buttwelding Fittings
B16.11 –Forged Fittings Socket-Welding and Threaded
B16.21 –Nonmetallic Gaskets for Pipe Flanges
American International (ASTM):
A123 –Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
A234 –Specification for Pipe fittings of Wrought Iron Carbon Steel and Alloy Steel for
Moderate and Elevated Temperature Service
A307 –Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength
A384 –Practice for Safeguarding Against Warpage and Distortion During Hot-Dip
Galvanizing of Steel Assemblies
A385 –Practice for Providing High Quality Zinc Coatings (Hot-Dip)
A563 –Specification for Carbon and alloy Steel Nuts
B6 –Specification for Zinc
D1330 –Specification for Rubber Sheet Gaskets
D6386 –Practice for Preparation of Zine (Hot-Dip Galvanized) Coated Iron and Steel
Products and Hardware Surfaces for Painting
E376 –Practice for Measuring Coating Thickness by Magnetic-Field or Eddy-Current
(Electromagnetic) Test Methods
F436 –Specification for Hardened Steel Washers
American Waterworks Association (AWWA):
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C200 –Standard for Steel Water Pipe-6 In. and Larger
C203 –Standard for Coal-Tar Protective Coatings and Linings for Steel Water
Pipelines-Enamel and Tape-Hot-Applied
C205 –Standard for Cement-Mortar Protective Lining and Coating for Steel Water
Pipe-4 In. and Larger-Shop Applied
C206 –Standard for Field Welding of Steel Water Pipe
C207 –Standard for Steel Pipe Flange for Waterworks Service. 4 In. Through 144 In.
C208 –Standard for Dimensions for Fabricated Steel Water Pipe Fittings
C210 –Standard for Liquid Epoxy Coatings and Linings for Steel Water Pipe and
Fittings
C213 –Standard for Fusion-Bonded Epoxy Coating for the Interior and Exterior of
Steel Water Pipelines
C219 –Standard for Bolted, Sleeve-Type Couplings for Plain End Pipe
C221 –Standard for Fabricated Steel Mechanical Slip-Type Expansion Joints.
C606 –Grooved and Shoulder Joints
National Science Foundation (NSF):
NSF/ANSI 61 –Drinking Water Components –Health Effects
1.4QUALITY ASSURANCE
Piping system manufacturer or fabricator shall have at least five (5) years experience in
producing products similar to those indicated for this Project and with a record of successful
in-service performance, as well as sufficient production capacity to produce required units.
1.5PROJECT CONDITIONS
Design Pressures:
Operating Pressure: Refer to Piping Schedule.
Surge Allowance: 40% of operating pressure.
o
Water Temperature: 90F maximum.
Hangers and Supports, Exposed Piping: Refer to Section 40 05 07“Hangers and Supports
for Piping Systems” for requirements for engineered hangers and supports for piping
systems to be provided by CONTRACTOR.
PRODUCTS
2.1PIPE AND FITTINGS
Pipe:
Pipe and fittings shall be manufactured or fabricated, coated, and lined (if applicable)
at a single location.
Referenced Standard: AWWA C200 or API Spec. 5L, Grade B.
Type:
6-Inch through 20-Inch: Mill or fabricated pipe, OD controlled.
24-Inch and Larger: Fabricated pipe, ID controlled.
Fabrication:
Except for seamless mill-type pipe, all piping shall be made from steel plates
rolled into cylinders or sections thereof with longitudinal butt welded seams as
indicated below, or shall be spirally formed and butt welded.
20-Inch and Smaller: One seam.
22-Inch to 54-Inch: Two seams.
56-Inch and Larger: Three seams.
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Girth seams shall be butt-welded and shall not be closer than six feet nor more
than 20 feet apart, except in specials and fittings.
Spiral lap welded steel pipe is not acceptable.
Circumferential deflection of all pipe in-place shall notexceed 2.0 percent of
pipe diameter.
Diameter:
Nominal pipe diameter shall be as shown on the Drawings. Unless otherwise
designated, nominal diameter shall be as follows:
Steel Pipe, Mortar Lining: Diameter shall be inside diameter of lining.
Steel Pipe, Coal-Tar or Epoxy Lining: Diameter shall be inside diameter of
pipe for 12-inch and smaller. Outside diameter of pipe for 14-inch and
larger.
Outside diameter of pipe shall be compatible with flanges, couplings, specials
and related work.
Wall Thickness:
General: In accordance with AWWA Design Manual M-11 for the internal and
external loads specified either on the Drawings or listed in the Piping Schedule.
Air Piping shall be Schedule 10 minimum.
Minimum Wall Thickness: As given in Table 15021-1.
Diameter RangeWall Thickness
(Inches)(Inches)
24 and under3/16
26 –361/4
38 –455/16
48 –543/8
57 –607/16
63 and larger1/2
Type Ends: As follows unless otherwise shown on the Drawings or specified.
Buried: Welded joints provided internal joints can be adequately coated after
welding.
Exposed or Submerged, Waste or Water Service: Flanged or plain ends with
couplings.
Plain: When flexible couplings of flanged coupling adapters are shown on
Drawings.
Exposed, Air Service: Welding is allowed prior to adding linings and coatings.
Field welds are not allowed. Any connections made after the linings and
coatings are added shall be done withflanges or restrained, flexible couplings.
o
Gaskets shall be suitable for 240F with lubrication oil present.
Coupling Coating: Fusion bonded epoxy interior and exterioror galvanized if
pipe is specified to be galvanized.
Fittings:
Welded:
Socket welded, forged steel per ANSI B16.11.
Butt-welded, steel per ANSI B16.9.
Wrought carbon steel fittings of seamless or welded construction per ASTM A234.
Fabricated steel fittings of same material as pipe per AWWA C208 and AWWA M-11.
2.2CONNECTIONS
Flanges:
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Comply with requirements of ANSI B16.1, Class 125; AWWA C207, Class D, Class E,
or Class F; or ANSI B16.5, Class 150 or Class 300, with class based on operating
conditions and mating flanges of valves, pumps and equipment.
Unless otherwise specified, provide slip-on type, flat face having a serrated finish.
Attached flanges to pipe with bolt holes straddling the vertical and centerlines of the
pipe.
Bolting Materials:
Bolting:
Exposed: ASTM A307, Grade B, hex head bolts; ASTM A563, Grade C, D, or
DH, hex head nuts; and ASTM F436 hardened steel washers.
Submerged or Buried: ASTM A193 or ASTM A320, Type 304 stainless steel
bolts; ASTM A194, Type 304, nuts; and washers of the same material as the
bolts.
Gaskets:
Standard: ANSI B16.1
Flange, Flat Face: Full-faced, 1/8-inch thick Neoprene,factory cut.
Flange, Raised Face: Use flat ring gasket.
Air Service:EPDM
Blind Flange Gasket: Cover entire inside surface, cementing to blind flange
surface.
Bolted, Sleeve-Type Couplings, Plain End Pipe: Comply with AWWA C219.
Couplings shall consist of one steel middle ring, length and thickness to be specified,
two follower flanges, two compounded wedged gaskets and a proper amount of bolts
to correctly compress the gaskets into the coupling for the application.
Expansion Joints, Mechanical Slip-Type: Comply with AWWA C221.
Expansion joints used on the hot-dip galvanized steel,low-pressure air piping serving
Sludge Storage Tank 1, Sludge Storage Tank 2, and Sludge Storage Tank 3 shall be
the Victaulic 231S type expansion coupling.
2.3LININGS AND COATINGS
Pipe and Fittings Interior:
Cement-Mortar: Applied in accordance with AWWA C205.
Coal-Tar Coating: Applied in accordance with AWWA C203 and Section09 91 00
“Painting and Protective Coatings.” Coating shall consist of surface preparation,
primer, and two coats of coal-tar enamel minimum dry film thickness per coat.
Liquid-Epoxy Coating: Applied in accordance with AWWA C210. The minimum applied
dry film shall be 16 mils.
Polyurethane Coating: Applied in accordance with AWWA C220. The minimum applied
dry film thickness shall be 20 mils.
Fusion-Bonded Epoxy Coating: Applied in accordance with AWWA C213. The
minimum applied dry film thickness shall be 12 mils.
Hot Dip Galvanized:
Preparation
Steel pipes and fittings shall be prepared before being galvanized per
ASTM D6386
Zinc metal used to galvanize the steel pipes and fittings shall be furnished
per ASTM B6
Coating
Steel pipes and fittings shall be hot-dipped galvanized per ASTM A123
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Follow the recommended practice for safeguarding against warpage and
distortion during hot-dip galvanizing of steel pipes and fitting shall be per
ASTM A384.
Hot dipped galvanized zinc coating shall be a minimum of 2.0 oz/sf of pipe
surface interior and exterior.
Finishing
Finish of the hot-dip galvanized pipe shall be tested per ASTM E376
Pipe and Fittings Exterior:
Coal-Tar Coating with Glass-Fiber Outerwrap: Applied in accordance with AWWA
C203.
Cold-Applied Tape Coating: Apply in accordance with AWWA C209. When specified,
cold-applied tape shall be used in conjunction with AWWA C203, AWWA C210, and
AWWA C219.
Liquid-Epoxy Coating: Applied in accordance with AWWA C210. The minimum applied
dry film shall be 16 mils.
Polyurethane Coating: Applied in accordance with AWWA C220. The minimum applied
dry film thickness shall be 20 mils.
Fusion-Bonded Epoxy Coating: Applied in accordance with AWWA C213. The
minimum applied dry film thickness shall be 12 mils.
Linings for air pipe, fittings, and couplings shall be suitable for temperatures of 240 ºF
and as specified in Section 41 34 23, paragraph 3.07.P.
2.4WALL PIPES AND SLEEVES
General: Laying lengths and endconnections to be as shown on Drawings.
Wall Thickness:
Wall pipes: Equal to or greater than that of adjoining pipe.
Wall sleeves: Standard weight.
Wall Collars:
Provide for all wall pipes to serve as a water stop and prevent axial movement of all
pipes.
Size Collars as follows:
Pipe SizeCollar O.D.Collar Thickness
(Inches)(Inches(Inches)
6 -12Pipe O.D. Plus 41/2
14 -18Pipe O.D. Plus 43/4
20 -24Pipe O.D. Plus 63/4
26 -42Pipe O.D. Plus 81
48 and largerPipe O.D. Plus 101-1/4
2.5PIPE DESIGN CLASSES
Pipe fittings and joints:
Designed for a minimum working pressure of 50psi (which includes surges and
thrusts), unless otherwise shown, as well as soil loads and stresses from thermal
expansion and contraction.
Test pressures shall be 75 psi, unless otherwise shown.
Fittings, specials and connections shall be same class as the associated pipe unless
otherwise indicated.
All pipe and fittings shall be clearly marked with the pressure class and piece number
to permit easy identification in the field.
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Buried Pipe Design:
Based internal and external loads imposed on the piping system. Refer to Section 31
23 00 “Excavation, Trenching and Backfilling for Utilities” and the Drawings for
information on trench embedment and backfill requirements.
Pipe shall be designed for the trench depths indicated using a Soil Reaction Modulus
E' of 1000, and a maximum pipe deflection of 2percent of D for mortar lined and
coated pipe (3% for mortar lined and flex coated; 5% for flexible lined and coated),
where D = Diameter.
EXECUTION
3.1INSTALLATION, CLEANING, AND TESTING
Comply with the requirements of Section 40 05 05“Piped Utilities,Basic Materials and
Methods.”
Restrained Joints: Unless otherwise indicated on the drawings, the CONTRACTOR shall use
mechanical restrained pipe joints and fittings (no thrust blocks). The length of pipe
requiring thrust restraint shall be calculated as described in Chapter 13 of AWWAM-11.
All joints requiring thrust restraint shall be welded (buried) in accordance with
AWWAC-206 or restrained with mechanical systems (exposed).
CONTRACTOR shall design restrained joints based on the specified pressures as
shown in the Piping Schedule or Drawings and in accordance with AWWA M-11.
The design for restrained joints,including the length necessary to resist the design
thrust, for the embedded conditions, shall be performed and sealed by a Professional
Engineer in the state where the Project is being constructed.
CONTRACTOR shall bear all costs for the design and will not receive reimbursement
from the OWNER.
Field Testing: Comply with the requirements of Section 40 01 05“Field Testing of Piping
Systems.” Minimum test Pressure shall be 75psi, if not shown otherwise.
3.2PIPING SCHEDUE
Piping Schedule shall either be as shown on the Drawings or after the ‘END OF SECTION.”
END OF SECTION
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SECTION 40 05 31.13
POLYVINYL CHLORIDE AND CHLORINATED POLYVINYL CHLORIDE PROCESS PIPE
GENERAL
1.1SUMMARY
Section provides requirements for PVC and CPVC piping systems and PVC wire reinforced
tubing for exposed and buried applications, pressure and gravity applications and includes:
Polyvinyl chloride (PVC) and chlorinated polyvinyl chloride (CPVC) pressure pipe and
fittings in sizes 1/2-inch through 60-inch.
Polyvinyl Chloride (PVC) and chlorinated polyvinyl chloride (CPVC) pressure pipe and
fittings.
Polyvinyl Chloride (PVC), Schedule 40 and 80, pressure pipe and fittings.
Polyvinyl Chloride wire reinforced pressure tubing and fittings (PVCT)
Related Work:
Refer to Section 40 05 05“Piping System,Basic Materialsand Methods” for infor-
mation regarding submittals; coordination; material delivery, handling, and storage;
projection conditions; design requirements; other materials; installation of piping sys-
tems; field testing; and related work.
This Section contains material requirements for pipe, fittings, specials, and appurte-
nances for PVC and CPVC piping systemsand PVC wire reinforced tubing system, as
well as Part 1-General and Part 3-Execution additional requirements not specified in
the above referenced Section.
1.2REFERENCES
Preselection Drawings and general provisions of the Contract, including Preselection Special
Conditions and Division 01 Specification Sections, apply to this Section.
Standards:
American Waterworks Association (AWWA):
C110 –Standard for Ductile-Iron and Gray-Iron Fittings, 3-In. Through 48-In.
(76 mm Through 1,219 mm) for Water
C111 -American National Standard for Rubber Gasket Joints for Ductile-Iron
and Gray-Iron Pressure Pipe and Fittings
C153 –Ductile-Iron Compact Fittings for Water Service
C219 –Standard for Bolted, Sleeve-Type Couplings for Plain-End Pipe
C900 –Standard for Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fit-
tings, 4-in. –60-in. (100 mm-300 mm) for Water Distribution
C907 –Standard for Injection-Molded Polyvinyl Chloride (PVC) Pressure Fit-
tings, 4-in. Through 12-in. (100 mm Through 300 mm)
F477 –Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.
F1417 –Test Method for Installation Acceptance of Plastic Gravity Sewer Lines
Using Low-Pressure Air
F1668 –Guide for Construction Procedures for Buried Plastic Pipe
F1674 –Test Method for Joint Restraint Products Used With PVC Pipe.
ASTM International, Inc. (ASTM):
D1785 –Specification for Poly(Vinyl Chloride)(PVC) Plastic Pipe, Schedule 40,
80, and 120
D2241 –Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Pressure-
Rated Pipe (SDR Series)
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D2466 –Specification for Poly(Vinyl Chloride)(PVC) Plastic Pipe Fittings, Sched-
ule40
D2467 –Specification for Poly(Vinyl Chloride)(PVC) Plastic Pipe Fittings, Sched-
ule80
D2564 –Specifications for Solvent Cements for Poly (Vinyl Chloride) (PVC) Plas-
tic Piping Systems
D2846 –Specifications for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic and
Hot-and Cold-water Distribution Systems
D3034 –Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and
fittings
F437 –Specification for Threaded Chlorinated Poly (Vinyl Chloride) (CPVC)
Plastic Pipe Fittings, Schedule 80
F438 –Specification for Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC)
Plastic Fittings, Schedule 40
F439 –Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Fittings,
Schedule 80
F441 –Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe,
Schedule 40 and 80
F442 - Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe
(SDR-PR)
F477 –Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe
F679 –Specification for Poly(Vinyl Chloride)(PVC) Large-Diameter Gravity
Sewer Pipe and Fittings
F794 –Specification for Poly(Vinyl Chloride)(PVC) Profile Gravity Sewer Pipe
and Fittings Based on Controlled Inside Diameter
F891 -Specification for Coextruded Poly(Vinyl Chloride)(PVC) Plastic Pipe With
a Cellular Core
F493 –Specification for Solvent Cements for Chlorinated Poly (Vinyl Chloride)
(CPVC) Plastic Pipe and Fittings
National Science Foundation (NSF):
NSF/ANSI 61 –Drinking Water Systems Components –Health Effects
1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Provide submittals in accordance with Section 40 05 05 “Piping Systems, Basic Materialsand
Methods.”
1.5QUALITY ASSURANCE –NOT USED
1.6DELIVERY, STORAGE, AND HANDLING
PVC materials to be stored on site longer than 6 months shall be covered to protect the pipe
against UV exposure.
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1.7SITE CONDITIONS–NOT USED
1.8WARRANTY–NOT USED
PRODUCTS
2.1PVC PIPE AND FITTINGS, 4-INCH THROUGH 60-INCH, PRESSURE
PVC Pressure Pipe: AWWAC900, Pressure class 80 psi -305 psi(as shown on Drawings or
in Pipe Schedule), with bell end with gasket, and with spigot end.
Comply with UL1285 for fire-service mains if indicated.
PVC Fabricated Fittings: AWWAC900, with bell-and-spigot or double-bell ends. In-
clude elastomeric gasket in each bell.
PVC Molded Fittings: AWWAC907,235 psi, with bell-and-spigot or double-bell ends.
Include elastomeric gasket in each bell.
Push-on-Joint, Ductile-Iron Fittings: AWWAC110, ductile-or gray-iron standard pat-
tern or AWWAC153, ductile-iron compact pattern.
Gaskets: AWWAC111, rubber.
Mechanical-Joint, Ductile-Iron Fittings: AWWAC110, ductile-or gray-iron standard
pattern or AWWAC153, ductile-iron compact pattern.
Glands, Gaskets, and Bolts: AWWAC111, ductile-or gray-iron glands, rubber
gaskets, and steel bolts.
PVC Integral Joint Restraint System:
Integral jointrestraint system located in the bell designed for integration into
PVC pipe manufactured to AWWA C900 and performance when tested in ac-
cordance with ASTM F1674.
Consists of a ductile iron casing that sits adjacent to the ASTM F477 gasket in
the bell; casing is molded into the raceway of the bell during pipe belling; and a
ductile iron grip-ring is inserted into the casing after factory hydro-testing.
Available Manufacturer: BullDog™Integral Joint Restrain System.
For restrained joints refer to Spectification Section 40 05 05 Part 2.5.F. Wedge
4
Action Restrains (Ductile Iron and PVC Pipe).
2.2CPVC/PVC PIPE AND FITTINGS, 6-INCH AND SMALLER, PRESSURE
PVC Pipe and Fittings: ASTMD1785, Schedule40 and Schedule 80 pipe, with plain ends for
solvent-cemented joints or threaded ends conforming to ASTMD2466, Schedule40 or
ASTMD2467, Schedule80, socket-type or threaded fittings. Use Schedule 80 for all pipes to
be threaded. Use Schedule 80 for all pipes to be threaded.
CPVC Pipe and Fittings: ASTM F441, Schedule40 and Schedule 80 pipe, with plain ends for
solvent-cemented joints or threaded ends conforming to ASTMF438, Schedule40 or
ASTMF439, Schedule80, socket-type or threaded fittings. Use Schedule 80 for all pipes to
be threaded.
Solvent Cement: As recommended by the pipe and fitting manufacturer conforming to
D2564 for PVC piping systems and ASTM F493 for CPVC piping systems.
2.3PVC PIPE AND FITTINGS, GRAVITY SEWER AND DRAIN
PVC Sewer Pipe and Fittings, NPS15 and Smaller: ASTMD3034, SDR26, with bell-and-
spigot ends for gasketed joints with ASTMF477, elastomeric seals.
PVC Sewer Pipe and Fittings, NPS18 and Larger: ASTMF679, PS 115, with bell-and-spigot
ends for gasketed joints with ASTMF477, elastomeric seals.
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2.4JOINING MATERIALS
Refer to Section40 05 05"Piping System, Basic Materialsand Methods" for commonly used
joining materials.
Plastic Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping sys-
tem manufacturer, unless otherwise indicated.
2.5POLYVINYL CHLORIDE WIRE-REINFORCED TUBING (HOSE)
PVC Tubing: Herco-Flex wire-reinforced PVC hose for transport of hypochlorite and bisulfite
under pressure used with compression fittings.
2.6PIPING SPECIALTIES
Transition Fittings: Manufactured fitting or coupling same size as, with pressurerating at
least equal to and ends compatible with, piping to be joined.
Tubular-Sleeve Pipe Couplings:
Description: Metal, bolted, sleeve-type, reducing or transition coupling, with center
sleeve, gaskets, end rings, and bolt fasteners and with ends of same sizes as piping
to be joined.
Standard: AWWAC219.
2.7CORROSION-PROTECTION
Ductile Iron Pipe Fittings Lining -When ductile iron pipe fittings are used on PVC pipe in
wastewater applications, including treated effluent, fittings shall be lined with an amine-
cured Novalac epoxy with at least 20percent by volume of ceramic quartz pigment, 40 mils
nominal DFT after the pipe has been solvent cleaned and abrasive blasted. Use Protecto
401 or approved equal.
Encasement for Underground Metal Pipe Fittings: ASTMA674 or AWWAC105.
Form: Sheet or tube.
Material: LLDPE film of 0.008-inch minimum thickness or high-density, cross-lami-
nated PE film of 0.004-inch minimum thickness.
Color: Black.
EXECUTION
3.1INSTALLER
Contractor
Comply with the requirements of Section 40 05 05“Piping System, Basic Materials
and Methods.”
3.2EXAMINATION –NOT USED
3.3PREPARATION –NOT USED
3.4INSTALLATION
CONTRACTOR shall comply with the installation requirements of Section 40 05 05 “Piping
System, Basic Materials and Methods.”
3.5FIELD/SITE QUALITY CONTROL
Field Testing:
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Comply with the requirements of Section 017525 “Equipment Testing and Startup”
Low pressure air piping systems shall be tested to 15 psi above operating pres-
sure unless otherwise indicated in the Pipe Schedule.
High pressure air piping systems shall be tested to 1.5 times the operating
pressure unless otherwise indicated in the Pipe Schedule.
3.6SYSTEM STARTUP –NOT USED
3.7CLOSEOUT ACTIVITIES –NOT USED
END OF SECTION
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PLUMMER ASSOCIATES, INC. 40 05 31.13 - PAGE 6 OF 6 BID SET
0537-038-01 POLYVINYL CHLORIDE AND CHLORINATED POLYVINYL CHLORIDE PROCESS PIPE JANUARY 2023
\\\\AUS-FS.AUS.APAI\\AUSTIN\\PROJECTS\\0982\\003-03\\2-0 WRK PROD\\2-3 SPECS\\3-BALANCE OF DESIGN SPECS\\DIVISIONS 40-49 PROCESS EQUIPMENT\\40 05 31.13
POLYVINYL CHLORIDE AND CHLORINATED POLYVINYL CHLORIDE PROCESS PIPE.DOCX
SECTION 40 0536.13
FOUL AIR FIBERGLASS DUCTWORK
PART 1 -GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SCOPE OFWORK
This specification covers requirements for fiberglass ductwork for the conveyance of foul air
as indicated on the plans and schedules. The duct system shall be furnished and installed
complete with all fittings, transitions, jointing materials, expansion joints, dampers,and all
other necessary appurtenances.
Duct and appurtenances will be continuously exposed to a humid environment containing
hydrogen sulfide and will be used in interior and exterior locations,as well as above and
below grade.
1.3REFERENCES
Drawings and general provisions of Contract, including General and Supplementary
Conditions and Division1 Specification sections, apply to work of this section.
Related Sections
Section 01 33 10, “Supplier’s Submittals.”
Section 09 91 00, “Painting and Protective Coatings.”
Section 40 05 31.13, “Polyvinyl Chlorideand Chlorinated Polyvinyl Chloride Process
Pipe.”
Section 40 05 64.43, “Fiberglass Dampers.”
Section 4431 16, “Carbon Adsorber Odor Control System.”
Reference Standards
ASTM D1599Standard test Method for Short-Time Hydraulic Failure Pressure of
Plastic Pipe, Tubing and Fittings.
ASTM D2105Standard test Method for Longitudinal Tensile Properties of
‘Fiberglass’ (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Tube.
ASTM D2412Standard Test Method for Determination of External Loading
Characteristics of Plastic Pipe by Parallel-Plate Loading.
ASTM D2992Standard Practice of Obtaining Hydrostatic or Pressure Design
Basis for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Fittings.
ASTM D2996Standard Specification for Filament Wound “Fiberglass”(Glass-
Fiber-Reinforced Thermosetting-Resin) Pipe.
ASTM D2997Standard Specification for Centrifugal Cast “Fiberglass”(Glass-
Fiber-Reinforced Thermosetting-Resin) Pipe.
ASTM D3567Standard Practice for Determining Dimensions of
“Fiberglass”(Glass-Fiber-Reinforced Thermosetting-Resin) Pipe.
AWWA M-45/C-950American Water Works Association Standard for Fiberglass
Pressure Pipe.
1.4QUALITY ASSURANCE
Minimum Duct Wall Stiffness: The minimum duct wall stiffness, at 5percent deflection,
determined in accordance with ASTMD2412 and Section3 of AWWAC950, shall not be less
than the following:
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0537-038-01FOUL AIR FIBERGLASS DUCTWORKJANUARY2023
Nominal Duct Diameter Duct Stiffness
(inches)(psi)
1-836
1018
12-169
18 and larger, buried10
18 and larger, other locations5
Buried ductand fittings shall be designed in accordance with AWWA C950 and AWWA M45.
Calculations using the AWWA M45 methodology shall be provided for each buried duct size
indicated on the drawings.
Temperature and Pressure: All duct, fittings, and appurtenances shall be suitable for the
following conditions:
ParameterDesign Condition
MinimumTemperature0°F
MaximumTemperature115°F
Internal Pressure25psig
Internal Vacuum20inches water column
Coefficient of Thermal Expansion: All ductwork, fittings and appurtenances shall have a
coefficient of thermal expansion not exceeding:
-6o
9.6 x 10in/in F for centrifugally cast pipe,
-6o
10.5 x 10in/in F filament wound pipe.
Expansion Joint Performance: Expansion joints shall be furnished in sufficient number to
accommodate the coefficient of thermal expansionbased on the minimum and maximum air
temperatures specified in this Section. Duct shall be protected from excessive solar heating
during storage and installation in accordance with Manufacturer's recommendations. All
thermal expansion and contraction throughout the duct system shall be accommodated in
expansion joints to be provided by the duct Manufacturer, and as shown on the Drawings.
AAAAAll Type 316 stainlesll Type 316 stainlesll Type 316 stainlesll Type 316 stainlesll Type 316 stainlesll Type 316 stainless steel materials shall include the following components:
Molybdenum: 2 –3%
Chromium: 16 –18%
Nickel: 10 –14%
1.5SUBMITTALS
Shop Drawings: Submit scaled layout drawings of fiberglass ductwork and fittings including,
but not limited to, duct sizes, locations, elevations, and slopes of horizontal runs, wall and
floor penetrations, and connections. Show interface and spatial relationship between
ductwork and proximate equipment. Show modifications of indicated requirements, made to
conform to local practice, and how those modifications ensure that free area, materials, and
rigidity are not reduced.
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1.6DELIVERY, STORAGE, AND HANDLING
Protection: Protect shop-fabricated and factory-fabricated ductwork, accessories and
purchased products from damageduring shipping, storage and handling as recommended
by the Manufacturer. Prevent end damage and prevent dirt and moisture from entering
ducts and fittings.
Storage: Where possible, store ductwork inside and protect from weather. Where
necessary to store outside, store above grade and enclose with waterproof wrapping as
recommended by the Manufacturer.
Comply with Manufacturer’s requirements.
PART 2 -PRODUCTS
2.1DUCTWORK MATERIALS
Vinyl Ester DuctVinyl Ester DuctVinyl Ester DuctVinyl Ester DuctVinyl Ester DuctVinyl Ester Duct
Centrifugally Cast, 14-inch andsmaller -ASTM D2997, RTRP-21B, centrifugally cast,
reinforced vinyl ester resin duct with 30mil liner.
NOV Fiber Glass Systems,"CentricastCL 1520"
Filament-Wound, 16-inch and smaller -ASTM D2996, RTRP-12ED-101, -12EF-311,
and -12EQ-311, or -12EU-311, with at least a 20mil reinforced liner
NOV Fiber Glass Systems, "F-Chem".
Beetle “Series 5000”.
Belco Manufacturing Co. Inc.
Daniel Company.
Filament-Wound, 18-inch and larger -ASTM D2310, RTRP-12ED, -11EQ, or -12EU,
with at least a 20mil reinforced liner
NOV Fiber Glass Systems,"F-Chem”.
Beetle “Series 5000”.
Belco Manufacturing Co. Inc.
Daniel Company.
Fittings and Flanges
Manufacturer's standard, glass fiber reinforced, compatible with the duct provided and
with chemical resistance equal to or greater than the duct. Flanges shall comply with
NIST PS15-69, Table5, at a design pressure of 25psi, and shall have a minimum of
ANSI/ASMEB16.1, Class25 diameter and drilling. All bends and elbows shall have a
centerline radius of at least 1.5 times the inside diameter of the duct. An eccentric
reducer shall be installed on the main or primary duct immediately upstream of the
wye fitting to increase the main duct size prior to the intersection with the lateral duct
in locations where size changes occur at intersections. Alternate bend and fitting
configurations may be considered by ENGINEER on a case-by-case basis where
existing site constraints prohibit installation of fittings shown on the Drawings.
Flange Bolts or Studs and Nuts
Type 316 stainless steel, sized such that, after installation, bolts will project 1/8-to
3/8-inch beyond the outer face of the nut.
Flat Washers -Type 316 stainless steel.
Flange Gaskets-Full face, ASTM D2240, TypeA durometer 50-70, 1/8-inch minimum
thickness, EPDM.
Bell-and-Spigot Joints-Matched tapered bell-and-spigotends bonded with adhesive.
Butt Joints-Butt and wrap, resin bonded, PS-15, with pressure rating equal to the duct.
Expansion Joints -As shown on the Drawings and specified herein.
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Adhesive -Duct Manufacturer's standard.
Straight Socket –Straight socket bonded with adhesive
All duct, fittings, and appurtenances shall contain ultraviolet (UV) inhibitors. All duct,
fittings, supports and appurtenances shall be painted to match the color of existing
ductwork. Painting shall be done in accordance with specification Section 09 91 00“Painting
and Protective Coatings”.
Caulking –Polyurethane-based, 1 part elastomeric sealant, Vulkem 921 by Maneco
International or equal. Use with compressible polyethene foam backer rod.
2.2FABRICATION
Joint Method: Unless otherwise specified, duct shall have straight socket, match tapered
bell and spigot or butt joints. Shop fabricated assemblies should be provided to the
maximum extent possible, to minimize the number of field joints.
Flanged joints shall be provided at each damper and item of equipment to facilitate
disassembly, at each change in material, at road crossings and where indicated on the
drawings.
Field butt joints, when needed, shall be made at locations at least 12inches from any
increasing or decreasing cross-section of duct where the duct to be jointed has the
same diameter. All bolts, nuts, washers, and gaskets required for all connections of
the ductwork system, including connections to equipment, shall be provided.
Transitions: Fiberglass reinforced plastic transition sections shall be furnished for connecting
round duct to rectangular openings on equipment. Transitions shall have a pressure rating
and wall stiffness equal to that of the duct. Internal lining shall be of the same type of
material and thickness as specified for the duct. Transitions shall have flanged end
connections compatible with the connecting duct and equipment. Transitions will be
constructed to provide for draining condensate in the direction of the airflow.
Expansion Joints: Expansion joints shall be furnished and installed at locations required for
proper duct installation. Expansion joints shall be resistant to ultraviolet light and shall be
suitable for the service conditions. All expansion joint materials in contact with the foul air
shall be manufactured of EPDM or other materials suitable for sustained contact in wet
hydrogen sulfide concentrations of up to 1500parts per million and dilute sulfuric acid. The million and dilute sulfuric acid. The million and dilute sulfuric acid. The million and
dilute sulfuric acid. The million and dilute sulfuric acid. The
duct Manufacturershall be responsible for selecting locations and quantities of expansion r selecting locations and quantities of expansion r selecting locations and quantities of expansion
joints based on the longitudinal and lateral movement capability of the specific expansion
joint product selected.
Expansion joints shall be flangedtype, as manufactured by Red Valve Co., Inc., Mercer
Rubber or approved equivalent. Hardware shall be Type 316 stainless steel.
2.3PIPE SUPPORTS
Details of construction of pipe support anchors and guides shall be as shown on the plans.
Manufacturer’s pipe shall be suitable for the support spacing shown on the plans. Duct
support spacings greater than 20feet may be considered by ENGINEER if modifications are
made to anchor bolts and to concrete support pads at no additional cost to OWNER. Duct
support spacings shall be as shown on the plans. All ductwork, guides, and anchors
supplied by Manufacturershall be capable of withstanding a 100-mile per hour lateral wind
load, and shall be capable of withstanding a 200pound concentrated vertical load (applied
over a 1square foot bearing area) at mid-span between any two supports.
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PART 3 -EXECUTION
3.1INSPECTION
General: Examine areas and conditions under which fiberglass ductwork is to be installed.
Do not proceed with work until unsatisfactory conditions have been corrected in manner
acceptable to Installer.
3.2INSTALLATION OF DUCTWORK
General: Assemble and install ductwork in accordance with recognized industry practices
which will achieve air-tight and noiseless (no objectionable noise) systems, capable of
performingeach indicated service. Install each run with minimum number of joints. Align
ductwork accurately at connections, within 1/8-inch misalignment tolerance and with
internal surfaces smooth. Support ducts rigidly with suitable ties, braces, hangers, and
anchors of type which will hold ducts true-to-shape and to prevent buckling. Support
vertical ducts at every floor or as recommended by Manufacturer.
Field Fabrication: Complete fabrication of work at project as necessary to match shop-
fabricated work and accommodate installation requirements.
Routing: Locate ductwork runs as indicated in the plans.
Coordination: Coordinate duct installations with installation of accessories, dampers,
equipment, controls, weir area covers, and other associated work of ductwork system.
Ductwork runs shall slope to the blower with the lowest point of the suction duct at the
entrance to the blower.
A condensate drain shall be provided at the low point in the suction ductwork and at
locations shown on the plans and shall be connected to the plant drain system.
3.3FIELD QUALITY CONTROL
Any ductwork found to be improperly installed shall be removed and replaced with
ductwork, liner or fittings meeting these specifications. Improper installation shall include,
but not be limited to, the following:
Fiberglass duct smaller than specified.
Construction joints not properly sealed.
Duct Manufacturershall provide the services of a trained factory representative to oversee
and coordinate duct installation. This factory representative shall make a minimum of one
trip to the project site, and shall spend a minimum of one 8-hour day at the project site,not
including travel time. The factory representative shall have at least 5years of experience
with installation of fiberglass duct systems similar to those required for this project. The
factory representative shall certify that the ductwork, supports, joints, and fittings have been
installed in accordance with Manufacturer's instructions, specifications, and other applicable
standards.
3.4EQUIPMENT CONNECTIONS
General: Connect ductwork to equipment as indicated, provide flexible connection for each
ductwork connection to equipment mounted on vibration isolators, and/or equipment
containing rotating machinery. Provide access doors as indicated.
3.5ADJUSTING AND CLEANING
Clean ductwork internally, unit by unit as it is installed, of dust and debris. Clean external
surfaces of foreign substances which might cause corrosive deterioration of fiberglass or,
where ductwork is to be painted, might interfere with painting or cause paint deterioration.
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Temporary Closure: At ends of ducts which are not connected to equipment or air
distribution devices at time of ductwork installation, provide temporary closure of
polyethylene film or other covering which will prevent entrance of dust and debris until time
connections are to be completed.
END OF SECTION
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SECTION 40 05 51
COMMON REQUIREMENTS FOR PROCESS VALVES
GENERAL
1.1SUMMARY
This Section includes the following general-duty valves:
Ball Valves, Bronze, 2-1/2 inches and smaller.
Ball Valves, Ferrous-Alloy, 2-1/2 inches and smaller.
Ball Valves, PVC, 6-inches and smaller.
Ball Valves, Stainless Steel, 12-inches and smaller.
Reduced Pressure Backflow Preventer Assembly, 2-1/2 inches to 10-inches
Diaphragm Valves, CPVC
Solenoid Valves
Valve appurtenances.
1.2REFERENCES
Preselection Drawings and general provisions of the Contract, including Preselection Special
Conditions and Division 01 Specification Sections, apply to this Section.
Abbreviations and Acronyms
Following are standard abbreviations used for valves:
CWP: Cold working pressure.
EDPM: Ethylene-propylene-diene terpolymer rubber.
NRS: Nonrising stem.
OS&Y: Outside screw and yoke.
PTFE: Polytetrafluoroethylene plastic.
SWP: Steam working pressure.
WOG: Water, oil and gas (Cold working pressure)
TFE: Tetrafluoroethylene plastic.
Related Sections:
Refer to Section 40 05 05 “Piping System,Basic Materialsand Methods” for
information regarding correlation with piping system submittals; coordination;
projection conditions; design requirements; other materials; installation of piping
systems; field testing; and related work.
Refer to Section 40 05 57.23 “Electric Motor Actuators.”
Refer to Section 40 05 62“Plug Valves”for eccentric plug valves.
1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Product Data: For each type of valve indicated. Include body, seating, and trim materials;
valve design; pressure and temperature classifications; end connections; arrangement;
dimensions; and required clearances. Include list indicating valve, its location in the project,
and its application. Include rated capacities; shipping, installed, and operating weights;
furnished specialties; and accessories.
Product Certificates: For each type of valve, from manufacturer.
Compliance with AWWA, ASTM, and ANSI standards including hydrostatic tests,
operational tests and other testing required by the standards.
Operation and Maintenance Data: Provide in accordance with Section 01 78 23“Operation
and Maintenance Data.”
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Field Quality Control: Provide field testing and performance reports.
Provide manufacturer’s warranty for all products indicated.
1.5QUALITY ASSURANCE
Obtain all valves of the same style and type, along with the associated manual operators,
from a single manufacturer.
NSF Compliance: NSF61, “Drinking Water Systems Components –Health Effects”for valve
materials for potable-water service.
Valve manufacturer shall demonstrate a minimum of five years of experience is similar
applications for size of valves furnished. References shall be provided upon request.
Valve supplier shall maintain a complete stock of parts in the state where the Project is
constructed or shall indicate that parts will be delivered upon 48-hour after receipt of
request.
1.6DELIVERY, STORAGE, AND HANDLING
Prepare valves for shipping as follows:
Protect internal parts against rust and corrosion.
Protect threads, flange faces, grooves, and weld ends.
Set angle, gate, and globe valves closed to prevent rattling.
Set ball and plug valves open to minimize exposure of functional surfaces.
Set butterfly valves closed or slightly open.
Block valves in either closed or open position.
Use the following precautions during storage:
Maintain valve end protection.
Store valves indoors and maintain at higher than ambient dew-point temperature. If
outdoor storage is necessary, store valves off the ground in watertight enclosures.
Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not
use handwheels or stems as lifting or rigging points.
PRODUCTS
2.1MANUFACTURERS
Available Manufacturers: Subject to compliance with requirements, available manufacturers
offering products that may be incorporated into the Work include, but are not limited to,
those listed in the valve descriptions.
2.2GENERAL
Valve to include operator, actuator, handwheel, chain wheel, extension stem, floor stand,
worm and gear operator, operating nut, chain, wrench, valve boxes, and all accessories and
related equipment for a complete operating system. Refer to P&ID Drawings for valves
requiring limit switches, electric or pneumatic operators, and related controls.
Comply with the following:
Service: Suitable for intended service, with valve pressure and temperature ratings
not less than indicated and as required for the system pressures and temperatures.
Valve Sizes: Same size as connection to upstream piping, unless otherwise indicated.
Valve Ends(Unless otherwise specified):
Compatible with adjacent pipingor equipmentconnections.
Bronze Valves: 2-inch and Smaller; threaded or soldered ends depending on
application.
Ferrous valves, 3-inch and Smaller: Threaded ends.
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Ferrous Valves, 3-inch and Larger:
Exposed Valves: Flanged ends.
Buried Valves: Mechanicaljoint ends.
Valves
Pressure Reducing: Provide a spring-loaded valve, with semi-steel body and stainless-
steelinner valve, disc seat and disc spring, adjusting spring of corrosion-resistance
steel and synthetic composition diaphragm, such as Fischer 630.
Pressure Relief: Furnish spring-loaded, bronze body relief valves with enclosed spring.
Use seats specially ground for compressed air service, Crosby Type AC with trip lever.
Gate Valves: For 2-1/2 inch and smaller, provide 150-lb solid disc, union bonnet,
rising stem gate valves.
Ball Valves: For 3inch andsmaller, provide ferrous alloy ball valve conforming to the
requirements of Section 40 05 51“Common Requirements for Process Valves.”
Valve Operator:
Operator sized to operate valve for full range of pressures and velocities.
Open by turning counterclockwise, clockwise to close, unlessotherwise specified.
Chainwheel: For attachment to valves, of size and mounting height, as indicated in
the "Valve Installation" Article in Part3.
Gear Drive Operator: For quarter-turn valves 8-inch and larger.
Handwheel: For valves other than quarter-turn types.
Lever Handle: For quarter-turn valves 6-inchand smaller.
Wrench: For valves with square heads. Furnish OWNERwith onewrench for every
10 valves, for each size square plug head.
Valves in Insulated Piping: Valves shall have 2-inchstem extensions and the following
features:
Gate Valves: Shall be rising-stem type.
Ball Valves: Shall have extended operating handle of non-thermal-conductive
material, protective sleeve that allows operation of valve without breaking the vapor
seal or disturbing insulation, and memory stops that are fully adjustable after
insulation is applied.
Butterfly Valves: Shall have extended necks.
Valve Flanges: ASMEB16.1 for cast-iron valves, ASMEB16.5 for steel valvesand
ASMEB16.24 for bronze valves.
Valve Grooved Ends: AWWAC606.
Solder Joint: With sockets according to ASMEB16.18.
Caution: Use solder with melting point below 840 degFfor angle, gate, and globe
valves; below 421 degFfor ball valves.
Threaded: With threads according to ASMEB1.20.1.
Valve Bypass and Drain Connections: MSSSP-45.
Factory assemblevalve with operator, actuator and accessories.
Fasteners for flanged valves shall be as follows: Comply with pipe joining material
requirements of Section 40 05 05 “PipingSystems, Basic Materialsand Methods.”
Obtain all valves of the same type and materials of construction with associated manual
operators from a single manufacturer
2.3MATERIALS
Brass and bronze valve components and accessories shall be made with dezincification-
resistant materials. Bronze valves made with copper alloy (brass) containingmorethan 15
percent zinc are not permitted.
Approved alloys are of the following ASTM designations:
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B61, B62, B98 (Alloy No. C65100, C65500, or C66100), B127, B139 (Alloy No.
C51000), B584 (Alloy UNS No. C90300 or C94700), B164, and B194.
Stainless steel, ANSI Type 316 may be substituted for bronze.
2.4FACTORY FINISHING
Interior Lining and Coating:
Interior ferrous metal surfaces of valve body, stem, actuator and related components
shall be epoxy coated in accordance with AWWA C550“Protective Epoxy Interior
Coatings for valves and Hydrants”,unless otherwise specified.
Epoxy coating material shall be NSF approved for use in potable water.
Either two-part liquid material or heat-activated (fusion) material except only heat-
activated material if specified as “fusion” or “fusion bonded” epoxy.
Color to match adjacent piping. Coating application to be accomplished in accordance
with Section 09 91 00 “Painting and Protective Coatings.”
Safety isolation and lockout valves with handles, handwheels, or chain wheels “Safety
Yellow.”
Exposed valves, other than above, paint handles, handwheels, or chain wheels “Red.”
Manufacturer shall apply shop primer coating on valves in the factory prior to delivery
with product described in Section 09 91 00“Painting and Protective Coatings.”
Contractor shall applyfinish coating with product described in Section 09 91 00
“Painting and Protective Coatings.”
Manufacturer shall apply shop primer coating on bonnets in the factory prior to
delivery with product described in Section09 91 00 “Painting and Protective
Coatings.” Contractor shall apply finish coating with product described in
Section099100 “Paintingand Protective Coatings.” Coating for submerged valves
shall apply to the submerged section of the bonnet plus 1’-0” above water surface.
Coatings for exterior valves shall be applied to the remaining section of the bonnet.
Exterior Coating
Manufacturer shall apply shop primer coating to valves and bonnet assemblies in the
factory prior to delivery with product described in Section09 91 00 “Painting and
Protective Coatings.”
2.5BALL VALVE
Bronze Ball Valves, General: MSSSP-110 and have bronze body complying with
ASTMB584, except for Class250 which shall comply with ASTMB61, full-depth ASME
B1.20.1 threaded or solder ends, and blowout-proof stems.
Two-Piece, Full-Port, Bronze Ball Valves with Bronze Trim: Chrome-plated bronze ball
and bronze stem and; reinforced TFE seats; threaded body packnut design (no
threaded stem designs allowed) with adjustable stem packing, solder or threaded
ends; and 150 psigSWP 600-psig CWP rating.
Manufactures:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
Two-Piece, Full-Port, Bronze Ball Valves with Stainless-Steel Trim: Type 316
stainless-steel vented ball and stem, reinforced TFE seats, threaded body packnut
design (no threaded stem designs allowed) with adjustable stem packing, soldered or
threaded ends; 150 psigSWP and 600-psigCWP ratings.
Manufactures:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
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Ferrous-Alloy Ball Valve, 3-inch and Smaller:
Split-body construction, ASTMA-216 Type WCB, carbon-steel body; ASTMA-351,
Type CF8M vented stainless-steelball; and ASTMA-276, Type 316 stainless-steel
stem; carbon-filled TFE seats; 285 psigCWP rating.
Fire rated according to API 607 (4th edition); and having flanged ends and blowout-
proof stem.
Conforms to MSS SP-72.
Manufactures:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
PVC/CPVC Ball Valve, 2-inches and Smaller:
True union type manufactured to ATSM F 1970 and constructed from PVC Type 1,
ASTM D 1784 Cell Classification 12454 or CPVC Type IV, ASTM D 1784 Cell
Classification 23447; O-rings shall be EDPM or Viton®; ball seats of PTFE; handles of
polypropylene; supplied with solvent-welded or threaded ends; approved for potable
°
water service; rated at 150 psi at73F; and shall be full port and block flow in both
directions.Ball shall be vented where indicated in drawings or specifications.
Manufacturer:
ASAHI-America.
Hayward.
NIBCO.
Georg Fischer.
PVC/CPVC Ball Valve, 3-inches through 6-inches:
True union type manufactured to ATSM F 1970 and constructed from PVC Type 1,
ASTM D 1784 Cell Classification 12454or CPVC Type IV, ASTM D 1784 Cell
Classification 23447; O-rings shall be EDPM; ball seats of PTFE; handles of
polypropylene; supplied with solvent-welded connections or flanged ends drilled to
ASME B16.4; approved for potable water service; provide a pressure relief hole drilled
on the low pressure side of ball; rated at 150 psi at73°F; and shall be full port and
block flow in both directions. Ball shall be vented where indicated in drawings or
specifications.
Manufacturers:
ASAHI-America.
Hayward
NIBCO.
Georg Fischer
Stainless Steel Ball Valve, ½-inch to 2-inches:
Three-piece body, full port, vented ball, blowout-proof stem, Type 316 stainless steel
trim, reinforced TFE seat and seal, threaded ends, lever operator, rated 1000-psi
CWP. Conforms to MSS SP-110.
Manufactures:
Contromatics.
Crane Valve Group
NIBCO.
Stainless Steel Ball Valve, 2-inches to 12-inches:
Unibody design, blowout-proof stem, Type 316 stainless steel trim, mounting pad, fire
safe, vented ball, flanged ends, rated 275-psi CWP. Conforms to MSS SP-72 and MSS
SP-25.
Manufactures:
NIBCO.
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2.6DIAPHRAGM VALVE, PLASTIC BODY
Type: Weir Type, constructed from CPVC Type IV, ASTM D 1784 Cell Classification 23447;
multiple layers of EPDM, PTFE, PVDF, or Viton®; flanged end connections; built-in position
indicator with polypropylene handwheel; reinforced polypropylene bonnet, stainless steel
hardware.
Pressure Rating:
1/2-inch through 4-inch: 150-psi at 73 degrees F
Manufacturers:
ASAHI America
Spears
2.7SOLENOID VALVE, 2-INCH AND SMALLER
Type: Two-way internal pilot operated diaphragm type, brass body, resilient seat suitable for
air or water, solenoid coil molded epoxy, NEMA Class A, 120 volts ac, 60-Hz, unless
otherwise indicated. Solenoid enclosure NEMA 250, Type 4, unless otherwise indicated.
Sizes and normal position (OPEN or CLOSED) as indicated.
Minimum operating pressure differential no greater than 5-psig, maximum operating
pressure differential not less than 125-psig.
Manufacturers:
ASCO
Skinner
2.8ACCESSORIES
Manual Operators:
Provide manual operators on valves, except those which are equipped with power
actuated operators or designed for automatic operation.
Operator force not to exceed 40 pounds under any operating conditions,
including initial breakaway. Gear reduction operator when force exceeds 40
pounds.
Operator self-locking or equipped with self-locking devices.
Position indicator on quarter-turn valves
Worm and gear operators one-piece design worm-gears of gear bronze
material. Worm hardened alloy steel with thread ground and polished.
Traveling nut type operators threaded steel reach rods with internally bronze or
ductile iron nut.
Exposed Operator:
Galvanized and painted handwheels.
Lever operators allowed on valves 6inches and smaller.
Cranks on gear operators.
Chain wheel operator with tie backs, extension stem, floor stands, and other
accessories to permit operation from normal operation level.
Valve handles to take a padlock and handwheels a chain and padlock.
Handwheels to comply with requirements of AWWA C500, Section 3.15
“Wrench Nuts and Handwheels.”
Buried Valves: WrenchNuts:
Buried Valves: 2-1/2 Inch and Smaller: Provide cross handle for operationby a
forked key.
Buried Valves, 3-Inch and Larger: Provide wrench nuts on buried valves, on
valves which are to beoperated through floor boxes and where shown on
Drawings.
Comply with requirements of AWWA C500, Section 3.15 “Wrench Nuts
and Handwheels.”
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Furnish no less than two operating keys for operation of wrench nut
operating valves.
Provide concrete pad, 2 foot square by 6-inch thick concrete around valve box
at ground surface.
Design buried service valves for quarter-turn valves to withstand 450 foot-pounds of
input torque at the fully open or FULLY CLOSED positions, grease packed and
gasketed to withstand a submersion in water to 10-psi.
Buried valves shall have a valve box. Valve box and bonnet shall be cast iron. All
components of shaft extensions shall be Type 316 stainless steel including nut shaft,
shaft housing and guides.
Extension stem diameter shall be1-inch or diameter of valve shaft, whicheveris
greater.
Stem guides made of cast iron with bronze bushingswith adjustable offset. Provide
stem guides at 5-foot intervals.
Above Ground Service:
3-inch and Larger: OS&Y, gear operators all valves 16-inch and larger unless
otherwise noted.
Chain Wheel Operator: Provide for valves having a centerline six feet or more above
the floor, unless otherwise noted.
Chain Wheel and Guide: Handwheel direct mounted, with galvanized or
cadmium-plated chain.
Operating Stands:
Provide fabricated steel or cast iron operating stands in locations shown on the
Drawings.
Support handwheel or operator approximately 36inches above finish floor.
Handwheel diameter will not be less than 8inches.
Provide sleeve made for opening in floor beneath each operating stand.
Provide suitable thrust bearing in each operating stand to carryweight of extension
stem.
Valve Boxes:
Cast iron, extension sleeve type, suitable for depth of cover required by Drawings.
Not less than 5inches in diameter and minimum thickness at any point of
3/16inches; provide valve boxes with suitable cast iron bonnets, bases and covers.
Provide covers; cast thereon an appropriate name designating service for which valve
is used.
When located in traffic areas, designed for H-20 loadings.
Set valves and valve boxes plumb; place each valve box directly over valve it serves,
with top of box flush with finished grade.
As shown on Drawings, provide concrete pad around valve surface box at ground
surface.
Extension Stem:
Provide extension stem when depth of valve is more than 3feetbelow finish grade.
Provide extension stem with wrench nut locating the wrench nut 6inches below
ground surface and/or box cover.
Extension stem shall locate wrench nut in floor box.
Floor Box and Stem: Plain type for support of non-rising type stem, complete with stem,
operating nut, and stem guide brackets. Provide stainless steel guides with adjustable offset.
Spacedsuch that stem L/R ratio does not exceed 200. Anchor bots to be Type 316 stainless
steel.
Torque Tube: Where operator for quarter-turn valve is located on floor stand, furnish
extension stem torque tube of a type properly sized for maximum torque capacityof valve.
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Identification: Provide valve identification tags in accordance with Section10 90 00
“Identification, Stenciling, and Tagging” and as specified in the various Valve Schedules and
as shown on the Drawings.
EXECUTION
3.1EXAMINATION
Examine piping system for compliance with requirements for installation tolerances and
other conditions affecting performance.
Proceed with installation only after unsatisfactory conditions have been corrected.
Examine valve interior for cleanliness, freedom from foreign matter, and corrosion. Remove
special packing materials, such as blocks, used to prevent disc movement during shipping
and handling.
Operate valves in positions from fully open to fully close. Examine guides and seats made
accessible by such operations.
Examine threads on valve and mating pipe for form and cleanliness.
Examine mating flange faces for conditions that might cause leakage. Check bolting for
proper size, length, and material. Verify that gasket is of proper size, that its material
composition is suitable for service, and that it is free from defects and damage.
Do not attempt to repair defective valves; replace with new valves.
3.2INSTALLATION
General:
Install valves, floorstands, valve boxes, and appurtenances in accordance with the
Drawings and manufacturer’s instructions.
Install valves and operators or actuators to provide for ease of access and operation.
Flanged Ends:
Bolt holes shall straddle vertical centerline of pipe.
Clean flange faces, insert gasket and bolts, and tighten nuts progressively and
uniformly.
Threaded Ends:
Clean threads by wire brushing or swabbing.
Apply joint compound.
Valve Installation:
Piping installation requirements are specified in other Sections. Drawings indicate
general arrangement of piping, fittings, and specialties.
Install valves with unions or flanges at each piece of equipment arranged to allow
service, maintenance, and equipment removal without system shutdown.
Locate valves for easy access and provide separate support where necessary.Provide
access doors in finished walls and plaster ceilings for valve access.
Install valves in horizontal piping with stem at or above center of pipe.
Butterfly valves will be installed with stem horizontal to allow support for the
disc and the cleaning action of the disc.
Unless otherwise noted, install operating stem vertical in horizontal runs of pipe
having centerline elevations 4feet6inches or less above finished floor.
Unless otherwise noted, install operating stem horizontal in horizontal runs of
pipe having centerline elevation between4feet6inches and 7feetabove
finish floor.
Install valves in position to allow full stem movement.
Install check valves for proper direction of flow and as follows:
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Swing Check Valves: In horizontal position with hinge pin level.
Dual-Plate Check Valves: In horizontal or vertical position, between flanges.
Lift Check Valves: With stem upright and plumb.
Butterfly valves shall be installed with stems horizontal.
If a plug valve seat position is not shown, locate as follows:
Horizontal low: The flow shall produce an “unseating” pressure; the plug shall
open into the top half of valve.
Vertical Flow: Install seat in the highest portion of the valve.
Install line size ball valve and union upstream of each solenoid valve, in-line flow
switch, or other in-line electrical device, excluding magnetic flowmeters for isolation
during maintenance.
Provide union or flanged connection within two feet of each threaded end valve
unless valve can be otherwise easilyremoved from piping.
Install safety isolation valves on compressed air lines which have stored energy in
accordance with latest OSHA requirements.
Valve Operators:
Manual Operators:
Provide manual operators on valves, except those which are equipped with
power actuated operators or designed for automatic operation.
Unless otherwise specified in the various valve sections, provide handwheel or
lever operators for valves,6-inch and smaller,and gear operators for valves,8-
inch and larger.
Buried Service:
2-1/2 inch and smaller:
3-inch and Larger (not installed in Valve Vault):
Provide stainless steel shaft extension and wrench nut. Minimum
extension stem diameter shall be 1-inch or diameter of valve shaft,
whichever is larger.
Provide valve box, bonnet and cover.
Wrench nut, handwheel and gear operator shall comply with the requirements
of applicable AWWA Standards.
As shown on the Drawings, buried Valves, 8-inch and larger, shall rest on
concrete pad. Pad shall extend full width of trench, from back-to-back of hub or
flange.
Above Ground Service:
3-inch and Larger: gear operators all valves 8-inch and larger,unless otherwise
noted.
Chain Wheel Operators: Install chainwheel operators on valves 4-inch and
larger and more than 84 inchesabove floor, unlessotherwise noted. Extend
chains to 60 inchesabove finished floor elevation.Where chains hang in
normally travel areas, use appropriate “L” type tie-back anchors.
Electric and pneumatic operators and actuators shall comply with the requirements of
Section 40 05 57.23 “Electric Motor Actuators.”
3.3FIELD COATING
Contractor shall apply finish coat with product described in Section09 91 00 “Painting
and Protective Coatings.”
For valves with bonnets and submerged in basins, the section of the bonnet assembly
below the top wall of the basin shall be coated with product described in Section 09
91 00 “Paintingand Protective Coatings.” Section of bonnet assembly above the
basin top of wall shall be coated with product described in Section099100 “Painting
and Protective Coatings.”
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Valve coating shall be applied in accordance with Sections09 91 00 “Painting and
Protective Coatings.”
3.4FIELD QUALITY CONTROL
Perform Tests and Inspections:
Valve may be either tested while testing pipelines, or as a separate step.
Test that valve opens and closes smoothly with operating pressure on one side and
atmospheric pressure on the other, in both directions for two-way valve and
applications.
Count and record the number of turns to open and close valve; account for any
discrepancies with manufacturer’s data.
Set, verify, and record set pressures for all relief and regulating valves.
Automatic valves to be tested in conjunction with control system testing and as
specified under Manufacturer’s services.
Prepare test and inspection reports.
3.5MANUFACTURERS’SERVICES
Manufacturer's Field Service: Engage a factory-authorized service representative to inspect
components, assemblies, and valve installations, including connections, and to assist in
testing.Provide in accordance with Section 01 43 33“Manufacturer’s FieldServices.”
For everythree (3)powered operated valves or gates, or less,provided on the Project, a
qualified manufacturers’ representative shall be present at the Project site for the minimum
person-days, travel excluded, as indicated:
Person-DaysActivity Description
1/2Inspection of valve installation, functional testing, and
certification valve assembly has been installed and tested in
accordance with manufacturer’s instructions and these
specifications.
1/2Plant startup.
1/2Training of OWNER”S personnel in operation and maintenance.
Startup Services; Comply with the requirements of Section 01 75 25“Equipment Testing and
Startup.”
Training of OWNER’S Personnel: Comply with the requirements of Section 01 79 00
“Demonstration and Training.”
END OF SECTION
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SECTION 40 05 52
MISCELLANEOUS VALVES AND APPURTENANCES
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
This Section includes the following general-duty valves:
Ball Valves, Bronze, 2-1/2 inches and smaller.
Ball Valves, Ferrous-Alloy, 2-1/2 inches and smaller.
Ball Valves, PVC, 6inches and smaller.
Ball Valves, Stainless Steel, 12inches and smaller.
Check Valves, Bronze 3-inch and smaller.
Check Valves, PVC, 4inches and smaller.
Check Valve, Iron Body, 3-inch and smaller.
Gate Valves, Bronze, 3-inch and smaller.
Gate Valve, Iron Body, 3-inch and smaller.
Globe Valves, Bronze, 3-inch and smaller.
Globe Valves, Cast Iron, 10-inch and smaller.
Angle valve, Bronze, 3inches and smaller.
Angle Valve, Iron body, 8-inch and smaller.
Angle Type Hose Valve.
Angle Pattern Hose Valve.
Diaphragm Valves,1/2-inch and larger.
Backflow Preventer, Reduce Pressure.
Instrument Air Shutoff Valve.
Gauge Cock
Corporation Stop.
Combination Balancing and Shutoff Valve.
Sampling valve.
Shear Gate Valve.
Mud valves.
Pressure Relief Valves.
Flap Gate.
Telescoping Valves.
Pressure Reducing Valves.
Solenoid Valves.
Valve appurtenances.
Related Sections:
Refer to Section 40 05 05 “Piping System,Basic Materialsand Methods” for
information regarding correlation with piping system submittals; coordination;
material delivery, handling, and storage; project conditions; design requirements;
other materials; installation of piping systems; field testing; and related work.
Valve and Related Lists: Lists are included for the convenience of the Engineer and
Contractor and are not complete listings ofall valves, devices and material to be provided
under this Contract. The Contractor agrees to prepare his own material and valve takeoff
lists as necessary to meet the requirements of the Project.
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1.3DEFINITIONS
Following are standard abbreviations used for valves:
CWP: Cold working pressure.
EDPM: Ethylene-propylene-diene terpolymer rubber.
NRS: Nonrising stem.
OS&Y: Outside screw and yoke.
PTFE: Polytetrafluoroethylene plastic.
SWP: Steam working pressure.
WOG: Water, oil and gas (Cold working pressure)
TFE: Tetrafluoroethylene plastic.
1.4SUBMITTALS
Product Data: For each type of valve indicated,include body, seating, and trim materials;
valve design; pressure and temperature classifications; end connections; arrangement;
dimensions; and required clearances. Include list indicating valve and its application.
Include rated capacities; shipping, installed, and operating weights; furnished specialties;
and accessories.
Product Certificates: For each type of valve, from manufacturer.
Compliance with AWWA, ASTM, and ANSI standards including hydrostatic tests,
operational tests and other testing required by the standards.
Operation and Maintenance Data: Provide in accordance with Section 017823“Operation
and Maintenance Data.”
Field Quality Control: Provide field testing and performance reports.
Manufacturer’s Warranty: Provide manufacturer’s warranty for all indicated products.
1.5QUALITY ASSURANCE
Obtain all valves of the same style and type, along with the associated manual operators,
from a single manufacturer.
NSF Compliance: NSF61, “Drinking Water Systems Components –Health Effects” for valve
materials for potable-water service.
Valve manufacturer shall demonstrate a minimum of five years of experience is similar
applications for size of valves furnished. References shall be provided upon request.
Valve supplier shall maintain a complete stock of parts in the state where the Project is
constructed or shall indicate that parts will be delivered upon 48-hour after receipt of
request.
1.6DELIVERY, STORAGE, AND HANDLING
Prepare valves for shipping as follows:
Protect internal parts against rust and corrosion.
Protect threads, flange faces, grooves, and weld ends.
Set angle, gate, and globe valves closed to prevent rattling.
Set ball and plug valves open to minimize exposure of functional surfaces.
Set butterfly valves closed or slightly open.
Block valves in either closed or open position.
Use the following precautions during storage:
Maintain valve end protection.
Store valves indoors and maintain at higher than ambient dew-point temperature. If
outdoor storage is necessary, store valves off the ground in watertight enclosures.
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Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not
use handwheels or stems as lifting or rigging points.
PRODUCTS
2.1MANUFACTURERS
Available Manufacturers: Subject to compliance with requirements, available manufacturers
offering products that may be incorporated into the Work include, but are not limited to,
those listed in the valve descriptions.
2.2GENERAL
Valve to include operator, actuator, handwheel, chain wheel, extension stem, floor stand,
worm and gear operator, operating nut, chain, wrench, valve boxes, and all accessories and
related equipment for a complete operating system. Refer to P&ID Drawings for valves
requiring limit switches, electric or pneumatic operators, and related controls.
Comply with the following:
Service: Suitable for intended service, with valve pressure and temperature ratings
not less than indicated and as required for the system pressures and temperatures.
Valve Sizes: Same size as connection to upstream piping, unless otherwise indicated.
Valve Ends (Unless otherwise specified):
Compatible with adjacent piping or equipment connections.
Bronze Valves: 2-inch and Smaller; threaded or soldered ends depending on
application.
Ferrous valves, 3-inch and Smaller: Threaded ends.
Ferrous Valves, 3-inch and Larger:
Exposed Valves: Flanged ends.
Buried Valves: Mechanical joint ends.
Valve Actuators:
Operator sized to operate valve for full range of pressures and velocities.
Open by turning counterclockwise, clockwise to close, unless otherwise specified.
Chainwheel: For attachment to valves, of size and mounting height, as indicated in
the "Valve Installation" Article in Part3.
Gear Drive Operator: For quarter-turn valves 8-inch and larger.
Handwheel: For valves other than quarter-turn types.
Lever Handle: For quarter-turn valves 6-inch and smaller.
Wrench: For valves with square heads. Furnish Owner with one wrench for every 10
valves, for each size square plug head.
Valves in Insulated Piping: Valves shall have 2-inch stem extensions and the following
features:
Gate Valves: Shall be rising-stem type.
Ball Valves: Shall have extended operating handle of non-thermal-conductive
material, protective sleeve that allows operation of valve without breaking the vapor
seal or disturbing insulation, and memory stops that are fully adjustable after
insulation is applied.
Butterfly Valves: Shall have extended necks.
Valve Flanges: ASMEB16.1 for cast-iron valves, ASMEB16.5 for steel valves and
ASMEB16.24 for bronze valves.
Valve Grooved Ends: AWWAC606.
Solder Joint: With sockets according to ASMEB16.18.
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Caution: Use solder with melting point below 840 degF for angle, check, gate, and
globe valves; below 421 degF for ball valves.
Threaded: With threads according to ASMEB1.20.1.
Valve Bypass and Drain Connections: MSSSP-45.
Factory assemble valvewith operator, actuator and accessories.
Fasteners for flanged valves shall be as follows: Comply with pipe joining material
requirements of Section 40 05 05“Piping System, Basic Materialsand Methods.”
Obtain all valves of the same type and materials of construction with associated manual
operators from a single manufacturer
2.3MATERIALS
Brass and bronze valve components and accessories shall be made with dezincification-
resistant materials. Bronze valves made with copper alloy (brass) containing more than 15
percent zinc are not permitted.
Approved alloys are of the following ASTM designations:
B61, B62, B98 (Alloy No. C65100, C65500, or C66100), B127, B139 (Alloy No.
C51000), B584 (Alloy UNS No. C90300 or C94700), B164, and B194.
Stainless steel, ANSI Type 316 may be substituted for bronze.
2.4FACTORY FINISHING
Interior Lining and Coating:
Interior ferrous metal surfaces of valve body, stem, actuator and related components
shall be epoxy coated in accordance with AWWA C550“Protective Epoxy Interior
Coatings for valves and Hydrants”, unless otherwise specified.
Epoxy coating material shall be NSF approved for use in potable water.
Either two-part liquid material or heat-activated (fusion) material except only heat-
activated material if specified as“fusion” or “fusion bonded” epoxy.
Minimum 12-mil dry film thickness except where limited by valve operating
tolerances. Epoxy coating shall be spark tested at the valve manufacturer’s factory in
accordance with AWWA C550 to verify uniform thickness. A certified test report on
valve manufacturer’s letterhead shall be supplied for each valve furnished.
Color to match adjacent piping. Coating application to be accomplished in accordance
with Section09 91 00“Painting and Protective Coatings.”
Safety isolation and lockout valves with handles, handwheels, or chain wheels “Safety
Yellow.”
Exposed valves, other than above, paint handles, handwheels, or chain wheels “Red.”
2.5BALL VALVE, BRONZE
Bronze Ball Valves, General: MSSSP-110 and have bronze body complying with
ASTMB584, except for Class250 which shall comply with ASTMB61, full-depth
ASMEB1.20.1 threaded or solder ends, and blowout-proof stems.
Two-Piece, Full-Port, Bronze Ball Valves with Bronze Trim: Chrome-plated bronze ball
and bronze stem and; reinforced TFE seats; threaded body packnut design (no
threaded stem designs allowed) with adjustable stem packing, solder or threaded
ends; and 150psig SWP 600psig CWP rating.
Manufacturers:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
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Two-Piece, Full-Port, Bronze Ball Valves with Stainless-Steel Trim: Type 316
stainless-steel vented ball and stem, reinforced TFE seats, threaded body packnut
design (no threaded stem designs allowed) with adjustable stem packing, soldered or
threaded ends; 150 psig SWP and 600-psig CWP ratings.
Manufacturers:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
PVC/CPVC Ball Valve, 3inches and Smaller:
Trueunion type manufactured to ATSM F 1970 and constructed from PVC Type 1,
ASTMD1784 CellClassification 12454 or CPVC Type IV, ASTM D 1784 Cell
Classification 23447; O-rings shall be EDPM or Viton®; ball seats of PTFE; handles of
polypropylene; supplied with solvent-welded or threaded ends; approved for potable
water service; having replaceable valve components; rated at 150 psi at73oF; and
shall be full port and block flow in both directions.
Manufacturer:
ASAHI-America.
Hayward.
NIBCO.
Spears.
Georg Fisher
IPEX.
PVC/CPVC Ball Valve, 4inches through 6inches:
True union type manufactured to ATSM F 1970 and constructed from PVC Type 1,
ASTMD1784 Cell Classification 12454 or CPVC Type IV, ASTM D 1784 Cell
Classification 23447; O-rings shall be EDPM; ball seats of PTFE; handles of
polypropylene; supplied with solvent-welded connections or flanged ends drilled to
ASMEB16.4; approved for potable water service; provide a pressure relief hole drilled
on the low pressure side of ball; rated at 150 psi at73degrees F; and shall be full
port and block flow in both directions.
Manufacturers:
ASAHI-America.
NIBCO.
Spears.
Georg Fisher
IPEX
2.6CHECK VALVE, IRON BODY
Class 125 Iron Body Check Valve, 3-inch and Smaller:
Class 125, iron body, horizontal swing, regrinding type, Y-pattern, renewable seat and
disc, 2-inch and smaller rated 125-psi SWP and 200-pound CWP, size 2-1/2-inch and
3-inch rated 150-psi SWP and 300-CWP, Conforms to MSS SP-70.
Manufacturers:
Crane
NIBCO
Powell, Wm. Co.
Stainless Steel Ball Valve, ½-inch to 2inches:
Three-piece body, full port, vented ball, block-out proof stem, Type 316 stainless steel
trim, reinforced TFE seat and seal, threaded ends, lever operator, rated 1000-psi
CWP. Conforms to MSS SP-110.
Manufacturers:
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Contromatics.
Crane Valve Group
NIBCO.
Stainless Steel Ball Valve, 2inches to 12inches:
Unibody design, blowout-proof stem, Type 316 stainless steel trim, mounting pad, fire
safe, vented ball, flanged ends, rated 275-psi CWP. Conforms to MSS SP-72 and
MSSSP-25.
Manufacturers:
NIBCO.
2.7GLOBE VALVES
Globe Valves: Class 125 Bronze Globe Valve, 3-inch and Smaller:
All bronze, screw-in bonnet, integral seat, renewable disc and seat, TFE seat,
threaded or soldered endsdepending on application, rated 125-psi SWP and 200-psi
CWP. Conforms to MSS SP-80.
Manufacturers:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
Class 150 Bronze Globe Valve, 3-inch and Smaller:
All bronze, union bonnet, integral seat, renewable disc and seat, threaded or soldered
ends depending on application, TFE disc, rated 150-psi SWP, 300-psi CWP. Conform
to MSS SP-80.
Manufacturers:
Crane Valve Group.
NIBCO.
Milwaukee Valve.
Class 125 Iron Body Globe Valve, 2-inch to 10-inch:
Cast iron, bolted bonnet, renewable seat and disc, bronze mounted, bronze disc and
seat ring, flanged ends, rated 125-psi SWP and 200-psi CWP. Conforms to MSS SP-85.
Manufacturers:
Crane Valve Group
NIBCO
Class 125 Bronze Angle Valve, 3inches and Smaller:
All bronze, union bonnet, integral seat, renewable seat and disc, TFE disc, threaded
or soldered endsdepending on application, rated 125-psi SWP, 200-psi CWP.
Conforms to MSS SP-80.
Manufacturers:
Crane Valve Group
NIBCO
Class 150 Bronze Angle Valve, 3inches and Smaller:
All bronze, union bonnet, integral seat, renewable seatand disc, TFE disc, threaded
ends, rated 150-psi SWP, 300-psi CWP. Conforms to MSS SP-80.
Manufacturers:
Crane Valve Group
NIBCO
Powell, Wm. Co.
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Class 125 Iron Body Angle Valve, 2-inch to 8-inch:
Cast iron, bolted bonnet, renewable seat and disc, bronze mounted, bronze disc and
seat ring, flanged ends, rated 125-psi SWP and 200-psi CWP. Conforms to MSS SP-85.
Manufacturers:
Crane Valve Group
NIBCO
Powell, Wm. Co.
Angle Type Hose Valve:
Bronze, angle sillcock type body, threaded or soldered inlet as applicable, 1/2-inch or
3/4-inch male hose thread outlet, rated125-psi CWP.
Manufacturer:
NIBCO
Angle Type Hose Valve:
3/4-inch NPT female inlet, 3/4-inch male hose thread outlet, heavy rough brass body,
rated 125-psi CWP, lockshieldbonnet, removable handle, atmospheric vacuum
breaker conforming to CSA and IAPMO code.
ACORN Engineering Co.;
Mounting on structure walls:
8120, bent nose with flange, without vacuum breaker.
8121, bent nose with flange, with vacuum breaker.
Installation on stand pipes:
8131, pipe and pedestal mounted valve located above 6inches, straight
nose.
8136, pipe and pedestal mounted valve lower than 6inches, inverted
nose.
Angle Pattern Hose Valve, 1-inch through 3-inch:
All-bronze, screwed ends, inside screw, rising stem, TFE disc, outlet of cast brass NHT
by NPT, male by male, nipple adapter with hexagonal wrench feature, brass cap with
chain, rated 300-psi CWP.
Manufacturer and Product:
Crane Valve Group; 7TF and 17TF
James Jones Co.; J-300 Series, angle fire hydrant valve with NPT inlet and NHT
outlet.
ITT Kennedy; Figure 936 angle fire hydrant valve with NPT inlet and NHT
outlet.
2.8DIAPHRAGM VALVES
Diaphragm Valves, 1/2-Inch and Larger:
Type: Weir type, polypropylene-lined cast iron body, ANSI B16.1 flangedends,
manual operator indicating rising stem type with handwheel, diaphragm neoprene, in
accordance with MSS-SP-88, Category B.
Manufactures:
ITT Engineered Valves.
Saunders Valve, Inc.
Diaphragm Valves, 1/2-Inch and Larger:
Type: Straight-through type, polypropylene-lined cast iron body, ANSI B16.1 flanged
ends, manual operator indicating rising stem type with handwheel, diaphragm
neoprene, in accordance with MSS-SP-88, Category B.
Manufacturers:
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ITT Engineered Valves.
Saunders Valve, Inc.
Diaphragm Valve, Plastic Body, 1/2-Inch and LargerSuitable for Sodium Hypochlorite
Service:
Type: Weir Type, constructed from CPVC Type IV, ASTM D 1784 Cell Classification
23447; multiple layers of EPDM, PTFE, PVDF, or Viton®; flanged end connections;
built-in position indicator with polypropylene handwheel; reinforced polypropylene
bonnet, stainless steel hardware.
Pressure Rating:
1/2-inch through 4-inch: 150-psi at 73degreesF.
6-inch: 100-psi at 73degreesF.
8-inch: 75-psi at 73degreesF
Manufacturer:
ASAHI America.
Spears.
2.9MISCELLANEOUS VALVES AND RELATED ITEMS
Reduced Pressure backflow Preventer:
Description: Two check valves, independent relief between the valves; NRS isolation
gate valves or ball valves, testing cock in accordance with AWWA C511, rated 175-psi
CWP, meet requirements of USC Cross connection Control Laboratory.
Manufacturers:
Cla-Val Company, Model RP Series
FEBCO; Model 825Y, 825YD.
Watts 909-QT RPZ
Instrument Air Shutoff Valve:
Stainless steel body and ball, nylon handle.
Manufacturer and Product:
Whitey; Series 40.
Imperial Eastman; Series 200.
Gauge Cock:
Description: 1/4-inch bronze body, hexagon end pattern, tee head, male ends, rated
125-psi CWP.
Manufacture and Product: United brass Works; Figure 973.
Corporation Stop:
AWWA C800 type, tapered threaded inlet, except when connecting to tapped fittings
which require IPS tapered threads, outlet compression connection or IPS threads to
suit connecting pipe, stop 1-inch and smaller rated 100-psi, larger stop rated 80-psi.
Manufacturers:
Ford Meter Box Co.
Mueller Co.
Combination Balancing and Shutoff Valve, 2inches and Smaller for Heating, Chilled, and
Cooling Water Service:
Description: Non-lubricated plug valve, cast iron or semi-steel body, wrench lever
manual operator, EPT resilient plug facing, adjustable memory stop, threaded ends,
rated 175-psi CWP.
Manufacturer:
DeZurick
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Sampling Valve:
Description: Insertion type, Type 304 stainless steel bonnet, Type 316 stainless steel
piston and stem, threaded end connections, hand crank, rated 600-psig CWP.
Manufactures and Products:
Strahman; SV700.
Shear Gate Valve:
Description: Full opening, circular port, standard frame, unless otherwise shown. Cast
iron body, ASTM A126, Class B, with integral flange, drilled for mounting; cast iron
gate, STM A126, Class B, replaceable wedges, two per gate, with adjustable stop;
bronze trim, Type 319 stainless steel bolts and hardware.
Manufactures and Products:
Clow Valve Co.; F3000
Mud Valves:
Description: Heavy-duty flanged type designed to provide positive seal under both
seating and unseating head conditions.
Floor Box and Position Indicator:
A position indicator shall be provided which shall be installed in a cast
iron floor box. The floor box shall be designed with internal flat sides to
prevent rotation of the position indicator during operations. The adapter
shall be provided with a bronze bushing to support and center the
extension stem. A non-corrosive debris shield shall be furnished and
installed into the cast iron floor box. The debris shield shall be designed
to fit tightly inside of the cast iron floor box. The top scale plate ofthe
position indicator shall have marking representing the number of turns,
contain the word “Closed” and a directional arrow. The markings shall
be permanently recessed, embossed or engraved in the scale plate. The
use of adhesive labels is not acceptable. The “open” line shall be
marked on a transparent polycarbonate window, which will be field
adjusted to the exact number of turns of each valve. The position
indicator shall be sealed with two (2) Neoprene O-rings. The position
indicator shall not admit more than 0.5 ounce of water, after 7 days of
submergence. The position indicator shall be cycle tested by the
manufacturer to insure successful operation of minimum 1 million
revolutions. Drop testing shall be performed by dropping an 18# weight
from 4 feet, to insure accidental impact will not crack or damage the
position indicator. The manufacturer shall support submergence, cycle
and impact testing with a report from an independent test laboratory.
Stem Guide:
The stem guide shall be of the adjustable design for plumb alignment.
The adjusting bolt and washer shall be type 316 stainless steel. Stem
guides shall be spaced so that the unsupported length between
extension stems shall not exceed 5 feet. Mud valves shall be operated
with extension stems, stem guides, and position indicators.
Materials: Body flange, yoke, guide, gate, extension stem, top nut, bottom coupling
and connection couplings shall be stainless steel, type 316. After machining, all
components shall be passivated in accordance with ASTM A-380; seat ring of resilient
seated configuration; cover seat consists of molded ring of Buna-N, nonrising stem,
316 stainless steelextension stem, 2-inch square operating nut for floor box or floor
stand operation. Flange drilling 125-lb ANSI.
As shown on the Drawings, provide pedestal lifts, stem guide, wall brackets and
related components for a complete operating assembly.
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Manufacturers and Products:
Clow Valve Co.; F-3075-T.
M&H Valve; Style 140-02
Waterman; MV 11.
Trumbull Industries, Inc.; 1367 Series
Pressure Relief Valves:
Wall Type, 4-Inch and 6-Inch:
Description: Hydrostatic pressure relief for side wall installation in structures
and basins. Valve shall be of the 100 offset with offset single pivoted hinge.
Materials: Body and flap gate,eitherstainless steel. Type 316,cast iron, ASTM
A126, Class B, or cast bronze, ASTM B584, Alloy 844, with integral ANSI 125-lb
flange; bronze trim, neoprene, ASTM D2000, rubber seat either retained by
cast iron retainer plate or mounted in a dovetail type groove; hinge arms cast
integrally with cover and attached utilizing a stainless steel spring pin.
Provide mating cast iron wall pipe shall be flange by plain end with internal
perforated plate.
Manufacturers and Products:
Clow Valve Co.; F-1494.
Waterman; PRB-14.
Trumbull Industries, Inc.; (1)367-1564
FloorType, 4-Inch and 6-Inch:
Description: Hydrostatic pressure relief valve designed for installing in the
bottom of concrete structures and basins.
Materials:
Body, cover, and grate shall be either stainless steel, type 316, cast iron,
ASTM A126, Class B, or cast bronze, ASTM B584, Alloy 844. Provide
neoprene, ASTM D2000, seat or seal either bonded to cover mating with
bronze seat in body or mounted in groove in cover.
Valve shall have either an integral PVC receiver or cast iron receiver,
including a water stop, to accept a plastic pipe extension which shall be
field cut to desired length. Provide either a cast iron or cast bronze
debris screen.
Manufacturers and Products:
Clow Valve Co.; F-1493-T.
Waterman; PRF-15.
Trumbull Industries, Inc.; (1)367-1544
Flap Gate (Gravity Flow):
Description: Circular opening for gravity flow conditions;body and flap, cast iron,
ASTM A126, Class B; bronze trim, neoprene seat; each hinge arm shall have two pivot
points, upper pivot point shall be adjustable to vary flap sensitivity to unseating
heads; Type 316 stainless steel bolts and hardware.
Manufacturers:
Rodney Hunt.
Waterman.
Flap Gate, Pressure Rated:
Description: Circular opening designed for pump discharge service; body and flap,
cast iron, ASTM A126, Class B; bronze trim, neoprene seat; each hinge arm shall have
two pivot points, upper pivot point shall be adjustable to vary flap sensitivity to
unseating heads; provide anti-locking bar between the two hinge pins to prevent
excessive rotation about the lower hinge pin; Type 316 stainless steel bolts and
hardware.
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Manufacturers:
Rodney Hunt.
Waterman.
Telescoping Valves:
Description: Assembly consists of a drain tube which can slip up and down inside a
stationary vertical pipe utilizing a lifting device to maintain the desired level. Primarily
used for sludge removal or liquid level control.
Rack and pinion type with offset floor stand and cast iron offset floor stem
incorporating the rack guides, pinion, and handwheel supports. Rack and pinion and
connecting rods Type 304 stainless steel, slip pipe brass with flared type skimming
funnel, cast iron pipe companion flange, O-ring seal, and gasket for connection to
discharge pipe.
Skimming Pipe Diameter: as shown on drawings.
Skimming Pipe Top Configuration
Valve Adjustment Height:
Provide pedestal, mounting brackets, stainless steel extension stem, stem guides,
Type316 anchor bolts and hardware, and all related components for a complete
assembly.
Manufactures and Products:
Waterman; TS-2
Link-Belt
Envirex
2.10SELF-CONTAINED AUTOMATIC VALVES
Pressure-Reducing Valve, 2-1/2 Inches and Smaller.
Type: Direct diaphragm operated, spring controlled, bronze body.
Size(s) and Rating(s): As shown in valve Schedule.
Manufacturers and Products:
Fisher; Type 75A.
Mueller; Series H-93 IO.
Pressure-Reducing Valve, 3inches and Larger:
Function:
Automatically reduces a higher inlet pressure to a steady lower downstream
pressure, regardless of changing flow rate and/or varying inlet pressure.
Pilot-operated regulator capable of holding downstream pressure to a pre-
determined limit. When downstream pressure exceeds the pressure setting of
the control pilot, the main valve and pilot valve close bubble-tight.
Main Valve: Hydraulically operated, single diaphragm-actuated, pilot controlled, globe
valve, consisting of:
Ductile iron, ASTM A536, or cast steel, ASTM A216-WCB, body and bolted
cover. All working parts shall be accessible without removal of the valve from
the line.
Disc Retainer and Diaphragm Washer: Cast Iron.
Trim: Disc guide, seat and cover bearing, bronze or stainless steel.
Disc: Buna-N rubber.
Stem, Nut and Spring: Stainless steel.
End Connections: Flange, 150 ANSI.
Flows: See Valve Schedule.
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Pilot Control System: Direct-acting, adjustable, spring-loaded, normally open,
diaphragm valve, designed to permit flow when pressure is less than the spring
setting.
Pilot Control: Bronze, ASTM B62.
Trim: Type 303 stainless steel.
Disc: Buna-N rubber.
Adjustment Ranges: See Valve Schedule.
Manufacturers and Products:
CLA-VAL; Model 90
Bermad; Model 720
GA Industries;
Solenoid Valve, 2-Inch and Smaller:
Type: Two-way internal pilot operated diaphragm type, brass body, resilient seat
suitable for air or water, solenoid coil molded epoxy, NEMA Class A, 120 volts ac, 60-
Hz, unless otherwise indicated. Solenoid enclosure NEMA 250, Type 4, unless
otherwise indicated.
Sizes and normal position (OPEN or CLOSED) as indicated.
Minimum operating pressure differential no greater than 5-psig, maximum operating
pressure differential not less than 125-psig.
Manufacturers:
ASCO
Skinner
Ball Valves, Electric Operated, 2-Inch and Smaller:
Type: Continuous duty rated true union ball valve with manual override and NEMA 4X
nonmetallic housing over actuator, closure time 6 seconds for 90o cycle.
Materials.
Body: PVC or CPVC to match piping, minimum pressure rating 230-psi.
Seals: EDPM or Vitron as applicable for intended service.
Motor: Heavy duty gear train, reversible motor with thermal overload switch,
120-volt, 60-Hz, with position indicator.
Manufactures and Products:
GF Model 346 ball valve with Type EA20 actuator and Type 126 bracket.
2.11APPURTENANCES
Manual Operators:
Provide manual operators onvalves, except those which are equipped with power
actuated operators or designed for automatic operation.
Operator force not to exceed 40 pounds under any operating conditions,
including initial breakaway. Gear reduction operator when force exceeds 40
pounds.
Operator self-locking or equipped with self-locking devices.
Position indicator on quarter-turn valves
Worm and gear operators one-piece design worm-gears of gear bronze
material. Worm hardened alloy steel with thread ground and polished.
Traveling nut type operators threaded steel reach rods with internally bronze or
ductile iron nut.
Exposed Operator:
Galvanized and painted handwheels.
Lever operators allowed on valves 6inches and smaller.
Cranks on gear operators.
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Chain wheel operator with tie backs, extension stem, floor stands, and other
accessories to permit operation from normal operation level.
Valve handles to take a padlock and handwheels a chain and padlock.
Handwheels to comply with requirements of AWWA C500, Section 3.15
“Wrench Nuts and Handwheels.”
Buried Valves: WrenchNuts:
Buried Valves: 2-1/2-Inch and Smaller: Provide cross handle for operation by a
forked key.
Buried Valves, 3-Inch and Larger: Provide wrench nuts on buried valves, on
valves which are to be operated through floor boxes and where shown on
Drawings.
Comply with requirements of AWWA C500, Section 3.15 “Wrench Nuts
and Handwheels.”
Furnish no less than two operating keys for operation of wrench nut
operating valves.
Provide concrete pad, 2-foot square by 6-inch thick concrete around valve box
at ground surface.
Design buried service valves for quarter-turn valves to withstand 450 foot-pounds of
input torque at the fully open or FULLY CLOSED positions, grease packed and
gasketed to withstand a submersion in water to 10-psi.
Buried valves shall have a valve box. Valve box and bonnet shall be cast iron. All
components of shaft extensions shall be Type 316stainless steel including nut shaft,
shaft housing and guides.
Extension stem diameter shall be 1-inch or diameter of valve shaft, whichever is
greater.
Stem guides made of cast iron with bronze bushingswith adjustable offset. Provide
stem guides at 5-foot intervals.
Chain Wheel and Guide: Handwheel direct mounted, with galvanized or cadmium-plated
chain.
Operating Stands:
Provide fabricated steel or cast iron operating stands in locations shown on the
Drawings.
Support handwheel or operator approximately 36inches above finish floor.
Handwheel diameter will not be less than 8inches.
Provide sleeve made for opening in floor beneath each operating stand.
Provide suitable thrust bearing in each operating stand to carry weight of extension
stem.
Valve Boxes:
Cast iron, extension sleeve type, suitable for depth of cover required by Drawings.
Not less than 5inches in diameter and minimum thickness at any point of 3/16-inch;
provide valve boxes with suitable cast iron bonnets, bases and covers.
Provide covers; cast thereon an appropriate name designating service for which valve
is used.
When located in traffic areas, designed for H-20 loadings.
Set valves andvalve boxes plumb; place each valve box directly over valve it serves,
with top of box flush with finished grade.
As shown on Drawings, provide concrete pad around valve surface box at ground
surface.
Extension Stem:
Provide extension stem when depth of valve is more than 3-feet below finish grade.
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Provide extension stem with wrench nut locating the wrench nut 6inches below
ground surface and/or box cover.
Extension stem shall locate wrench nut in floor box.
Floor Box and Stem: Plain type for support of non-rising type stem, complete with stem,
operating nut, and stem guide brackets. Provide stainless steel guides with adjustable offset.
Spaced such that stem L/R ratio does not exceed 200. Anchor bots to be Type 316 stainless
steel.
Torque Tube: Where operator for quarter-turn valve is located on floor stand, furnish
extension stem torque tube of a type properly sized for maximum torque capacity of valve.
Identification: Provide valve identification tags in accordance with Section 1090 00
“Identification, Stenciling, and Tagging” and as specified in the various Valve Schedules and
as shown on the Drawings.
EXECUTION
3.1EXAMINATION
Examine piping system for compliance with requirements for installation tolerances and
other conditions affecting performance.
Proceed with installation only after unsatisfactory conditions have been corrected.
Examine valve interior for cleanliness, freedom from foreign matter, and corrosion. Remove
special packing materials, such as blocks, used to prevent disc movementduring shipping
and handling.
Operate valves in positions from fully open to fully close. Examine guides and seats made
accessible by such operations.
Examine threads on valve and mating pipe for form and cleanliness.
Examine mating flange faces for conditions that might cause leakage. Check bolting for
proper size, length, and material. Verify that gasket is of proper size, that its material
composition is suitable for service, and that it is free from defects and damage.
Do not attempt to repair defective valves; replace with new valves.
3.2INSTALLATION
General:
Install valves, floorstands, valve boxes, and appurtenances in accordance with the
Drawings and manufacturers instructions.
Install valves and operators or actuators to provide for ease of access and operation.
Install buried valve
Flanged Ends:
Bolt holes shall straddle vertical centerline of pipe.
Clean flange faces, insert gasket and bolts, and tighten nuts progressively and
uniformly.
Threaded Ends:
Clean threads by wire brushing or swabbing.
Apply joint compound.
Valve Installation:
Piping installation requirements are specified in other Division40Sections. Drawings
indicate general arrangement of piping, fittings, and specialties.
Install valves with unions or flanges at each piece of equipment arranged to allow
service, maintenance, and equipment removal without system shutdown.
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Locate valves for easy access and provide separate support where necessary.Provide
access doors in finished walls and plaster ceilings for valve access.
Install valves in horizontal piping with stem at or above center of pipe.
Butterfly valves will be installed with stem horizontal to allow support for the
disc and the cleaning action of the disc.
Unless otherwise noted, install operating stem vertical in horizontal runs of pipe
having centerline elevations 4feet 6inches or less above finished floor.
Unless otherwise noted, install operating stem horizontal in horizontal runs of
pipe having centerline elevation between 4feet 6inches and 7feet above
finishfloor.
Install valves in position to allow full stem movement.
Install check valves for proper direction of flow and as follows:
Swing Check Valves: In horizontal position with hinge pin level.
Dual-Plate Check Valves: In horizontal or vertical position, between flanges.
Lift Check Valves: With stem upright and plumb.
Butterfly valves shall be installed with stems horizontal.
If a plug valve seat position is not shown, locate as follows:
Horizontal low: The flow shall produce an “unseating” pressure; the plug shall
open into the top half of valve.
Vertical Flow: Install seat in the highest portion of the valve.
Install line size ball valve and union upstream of each solenoid valve, in-line flow
switch, or other in-line electrical device, excluding magnetic flowmeters for isolation
during maintenance.
Provide union or flanged connection within two feet of each threaded end valve
unless valve can be otherwise easily removed from piping.
Install safety isolation valves on compressed air lines which have stored energy in
accordance with latest OSHA requirements.
Valve Operators:
Manual Operators:
Provide manual operators on valves, except those which are equipped with
power actuated operators or designed for automatic operation.
Unless otherwise specified in the various valve sections, provide handwheel or
lever operators for valves, 6-inch and smaller, and gear operators for valves, 8-
inch and larger.
Buried Service:
2-1/2-inch and smaller:
3-inch and Larger (not installed in Valve Vault):
Provide stainless steel shaft extension and wrench nut. Minimum
extension stem diameter shall be 1-inch or diameter of valve shaft,
whichever is larger.
Provide valve box, bonnet and cover.
Wrench nut, handwheel and gear operator shall comply with the requirements
of applicable AWWA Standards.
As shown on the Drawings, buried Valves, 8-inch and larger, shall rest on
concrete pad. Pad shall extend full width of trench, from back-to-back of hub or
flange.
Above Ground Service:
3-inch and Larger: gear operators all valves 8-inch and larger, unless otherwise
noted.
Chain Wheel Operators: Install chain wheel operators on valves 4-inch and
larger and more than 84 inches above floor, unless otherwise noted. Extend
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chains to 60inches above finished floor elevation. Where chains hang in
normally travel areas, use appropriate “L” type tie-back anchors.
Electric and pneumatic operators and actuators shall comply with the requirements of
the applicable Division 40operator section.
3.3FIELD QUALITY CONTROL
Perform Tests and Inspections:
Valve may be either tested while testing pipelines, or as a separate step.
Test that valve opens and closes smoothly with operating pressure on one side and
atmospheric pressure on the other, in both directions for two-way valve and
applications.
Count and record the number of turns to open and close valve; account for any
discrepancies with manufacturer’s data.
Set, verify, and record set pressures for all relief and regulating valves.
Automatic valves to be tested in conjunction withcontrol system testing and as
specified under Manufacturer’s services.
Prepare test and inspection reports.
3.4MANUFACTURERS’ SERVICES
Manufacturer's Field Service: Engage a factory-authorized service representative to inspect
components, assemblies, and valve installations, including connections, and to assist in
testing. Provide in accordance with Section 01 43 33“Manufacturer’sField Services.”
For every powered operated valves or gates, or less, provided on the Project, a
qualified manufacturers’ representative shall be present at the Project site for the minimum
person-days, travel excluded, as indicated:
Person-DaysActivity Description
1/2 Inspection of valve installation, functional testing, and
certification valve assembly has been installed and tested in
accordance with manufacturer’s instructions and these
specifications.
1/2 Plant startup.
1/2 Training of OWNER’S personnel in operation and maintenance.
Startup Services; Comply with the requirements of Section 01 75 25“Equipment Testing and
Startup.”
Training of OWNER’S Personnel: Comply with the requirements of Section 01 79 00
“Demonstration and Training.”
3.5VALVE SCHEDULE
Refer to Valve Schedules provided either on the Drawings or in the various individual valve
sections for additional information.
The Valve Schedule after the END OF SECTIONshall be part of this Section. The Valve
Schedule is not guaranteed to be accurate, and list valves 6-inch and larger, unless it is a
control valve. Refer to Drawings for type, end connections, and locations for all valves.
END OF SECTION
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SECTION 40 05 57.23
ELECTRIC MOTOR ACTUATORS
GENERAL
1.1SUMMARY
Scope and Supply
It shall be the EQUIPMENT SUPPLIER's responsibility to provide fully integrated
valve/gate/actuator as a complete operation unit. When listed below the
manufacturer refers to the actuator manufacturer.
Section Includes:
Electric motor actuators, both multi-turn and quarter-turn, isolation and
modulating/throttling for valves and gates.
Related Sections:
Refer to Section 40 05 51“Common Requirements for Process Valves” for information
regarding submittals; coordination; material delivery, handling, and storage;
projection conditions; design requirements; other materials; installation of valves;
field testing; and related work.
Refer to various Division 40valve or gate sections for information regarding the valve
or gate on which the operator will be installed.
1.2REFERENCES
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
Standards
American Water Works Association (AWWA):
C540 -Power-Actuating Devices for Valves and Sluice Gates
1.3ADMINISTRATIVE REQUIREMENTS-NOT USED
1.4SUBMITTALS
Submittals shall be prepared and submitted for review in accordance with Section 013300
“Submittal Procedures”.
Action Submittals
As part of the applicable control valve or gate submittal, provide the following
information:
Product Data: Construction details, material descriptions, dimensions of
individual components and profiles, rated capacities, operating characteristics,
electrical characteristics, and furnished specialties and accessories.
Shop Drawings: Provide plans, elevations, sections, details, and
attachments to other work.
Layout drawings including all proposed system components with
dimensions, clearances required and sizes indicated, and arrangement
and size of connections.
Specific design parameters for this project as specified herein.
Adjustable settings with range provided for valve opening, closing, and
emergency closing speeds.
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Sequenced operational control description indicating adjustment ranges
and set points for each device and resulting action for failure to complete
the individual sequences.
Wiring Diagrams: For power, signal, and control wiring diagrams,
including terminals and numbers.
Information Submittals
Qualification Data: For manufacturer and manufacturer’s representative.
Suggested spare parts list to maintain the equipment in service for a period of two
years. Include a list of special tools required for checking, testing, parts replacement,
and maintenance with current pricing information.
Qualification Data: For qualified manufacturer and factory-authorized service
representative.
Source quality-control reports.
Manufacturer’s warranty for all indicated products.
Closeout submittals
Operation and Maintenance Data: Provide in accordance with Section 017823
“Operation and Maintenance Data.”
1.5QUALITY ASSURANCE
Manufacturer Qualifications:
Electric motor operators shall be the product of a manufacturer having at least ten
(10) U.S. installations of the type being proposed, each with a minimum of 5years of
satisfactory service.
A list of similar installations shall be furnished with the shop drawing submittal,
including names and telephone numbers of contacts.
Installer Qualifications: Manufacturer's authorized representative who is trained and
approved for installation of units required for this Project.
SourceLimitations: Valve actuator shall be furnished integral with the control valve, along
with accessories, by the supplier of the control valve.
Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA70,
by a qualified testing agency, and marked for intended location and application.
1.6DELIVERY, STORAGE, AND HANDLING
Deliver, handle, and store all components to be installed under this section in accordance
with the manufacturer’s written Pre-Installation Delivery, Storage, and Handling Instructions
and the requirements of Section 01 60 00 “Product Requirements.”
1.7SITE CONDITIONS
The equipment, sizes, materials, and arrangements described in this section are based on
recommendations by equipment suppliers and shall be considered minimum limits of
acceptability. The manufacturershall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
Environmental Conditions:
All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipalwastewater treatment plants.
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All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 110°F, with indoor operating temperature of140°F.
1.8WARRANTY
Extended Equipment Warranty: Refer to Section017836 “Warranties” for extended
equipment warranty.
All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
PRODUCTS
2.1MANUFACTURERS
Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include:
Rotork; IQ Series
No like, equivalent, “or-equal” item or substitution is permitted.
2.2SYSTEMS COMPONENTS
General Requirements:
The actuators shall be suitable for use on a 460 volt3 phase 60 Hz power supply and
must include motor, integral reversing starters, local controls and terminals for remote
control and indication housed within a self-contained, sealed enclosure.
Set-up of the actuator shall be carried out without the removal of any covers.
Actuator calibrations shall be integral pushbuttons and selector switches. No separate
special commissioning tools shall be required, although unit shall be capable of
configuration from a handheld unit.
In additional, provision shall be made for the protection on configured actuator
settings by means of a password.
The use of a manufacturer's name and model number or catalog number is for the
purpose of establishing a standard of quality and general configuration desired.
Like items ofmaterials/equipment shall be the end products of one manufacturer in
order to provide standardization for appearance, operation, maintenance, spare parts,
and manufacturer's service.
Operators shall be fully self-contained, conforming AWWA C540, except asherein
modified.
PERFORMANCE REQUIREMENTS
Design Requirements: Control valve, operator, and accessories shall comply with the
following general requirements:
Actuators and appurtenances shall be designed for the conditions and
requirements as specified inthe respective valve sections.
Liberal factors of safety shall be used throughout the design, especially in the
design of parts subject to intermittent or alternating stresses. In general,
working stresses shall not exceed 1/3 of the yield point or 1/5 of the ultimate
strength of each material.
Designed for the project conditions described in Project Conditions paragraph.
Supports, anchors and fasteners shall be of adequate strength to withstand
loads associated with opening, closing, turbulence, thrustsfrom liquid
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movement, thermal expansion and contraction and other loads encountered
under normal operating conditions.
Fasteners and hardware shall be Type 316 stainless steel. Mounting brackets
that are exposed to the water or to seal or packing leakage shall be Type 316
stainless steel or other acceptable non-corrosive material.
Compliance with AWWA, ASTM, and ANSI standards including hydrostatic tests,
operational tests and other testing required by the standards.
Valve actuators:
Each actuator shallbe designed to open or close the valve under operating
conditions.
The actuators and gear train shall be designed for the full design head rating of
the valve or gate and the actual fluid velocity through the valve or gate not less
than 16 fps.
Valve actuators shall be provided and adjusted by the Valve Manufacturer.
Actuator mounting arrangements and positions shall facilitate O&M and shall be
determined by the Valve Manufacturer unless shown otherwise on the
Drawings or directed by the ENGINEER.
Pump control valves: Valves shall provide controlled opening and closing of the
pump discharge valve actuator. The pumps will be started and stopped against
a closed valve imposing full pump shut-off head on the valve when closed.
Electrical/Controls
For modulating duty, the starter shall be solid-state type suitable for up to a
maximum of 1,200 starters per hour. Actuator shall be cable of responding to a
remote4-20 mA control signal and positioning itself accordingly between 0-100%
valve travel as well as provided a contactless transmitter to give a 4-20 mA analog
signal corresponding to valve travel for remote indicated. The control module shall
contain adjustments for span, zero, gain, and deadband.
For Open/Close (Isolation) duty, the starter shall be elector-mechanical type suitable
for 60 starters per hours and of rating appropriate to motor size. Discrete remote
control may be configured as two, three or four wires for open-stop-close control.
Remote control functions may be powered by external 24 Vdc, 120 Vac or the
actuator's internal 24 Vdc supply.
Local Indication and Control:
The actuator shall include a graphical LCD and LED indicators.
Provide local control stations integral to each operator consisting of either selector
switches or pushbuttons.
Monitor Relay:
A monitor relay shall be included and shall trip with the actuator is not available for
remote operation. The monitor relay shall be configurable for these fault indicators:
loss of phase, valve hammed, overtorque, inhibit ESD and motor over temperature. A
LED shall blink when the monitor relay is active. Both normally open and normally
closed contact shall be provided, rated 120 Vac, 0.5 Amp.
Emergency Shut Down (ESD):
An Emergency Shut Down (ESD) provides shall be included in each actuator. The
actuator shall permit inputs for ESD and they shall be configurable. The ESD signal
shall override any existing signals (expect LOCAL, STOP and INHIBIT) san send the
valve to its configured emergency position
Phase Correction Circuit:
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A phase correct circuit shall be included to correct motor rotation faultscaused by
incorrect site wiring. The phase correction circuit shallalso detect the loss of a phase
and disable operation to percent motor damage.
Status Contacts:
Provide four (4) status latched status contacts rated at 120 Vac, 0.5 A and 30 Vdc, 2
A for remote indicate of valve position, configured as 1-normally open and 1 normally
closed for both the open and closed positions. Two contacts may be configured to
represent any other actuator status.
Torque Switches:
Torque switch shall be an electronic sensor, adjustable from 40 to 100% of torque
limit in 1 % increments. The motor shall be de-energized if the torque limits is
exceeded. A boost function shall be included to percent torque trip during initial
valve/gate unseating, a "Jammed Valve" protection feature, with automatic retry
sequence, shall be incorporated tode-energize the motor if no movement occurs.
Handheld Device
Provide two (2) handheld devices to allow configuration of the actuator for up to 10
meters from the actuator in all directions.
Heaters:
Actuators shall have provisions for space heaters powered from an internally derived
power surge and power source.
Motor Requirements:
Manufacturer’s designed for applicable valve or gate operator service; high torque,
totally enclosed, non-ventilated construction, with motor leads brought into the limit
switch compartment without having external piping or conduit box.
Capable of seating and unseating the valve or gate against maximum differential
pressure when voltage to the motor terminals is 10 percent above or below nominal.
Pre-lubricated, suitable for year-round service based at prevailing ambient
temperature conditions, and with bearings of the antifriction type.
Motor shall have Class H insulation, with thermistor imbedded in the motor windings,
and rated for 30-minute continuous duty.
Actuator Sizing Requirements:
The actuator shall be sized to guarantee valve closure at the specified torque and/or
thrust requirement as indicated by the valve or gate manufacturer or supplier.
Produce actuator output of 1 1/2 times the required valve operating torque.
The actuator must be adequately sized to provide the torque required to operate the
valve at 90% of the nominal voltage.
The operating speed shall provide valve closing and opening at approximately 12
inches per minute for gate valves, 4 inches per minute for globes valves and as
indicated in the valve list for quarter turn valves. If not listed in the valve list, quarter
turn valves shall operate at 1 minute. Slide, sluice, and weir gates shall operate at
approximately at 12 inches per minute. Quarter valves will be furnished with
mechanical stops that restrict the valve/actuator travel.
Enclosure:
Actuator shall be O-ring sealed, water tight to NEMA 4X/6. When required, actuators
for hazardous locations shall be certified explosion proof for Class I, Division 1 & 2,
Groups C & D. Enclosure must allow for temporary site storage without the need for
electrical supply connection. All external fasteners shall be of stainless steel. Gear
case shall be cast iron.
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Unit Gearing:
Motorspeed reduction accomplished a gear train consisting of spur gears of heat
treated steel and self-locking worm and worm gear set.
Worm gearing shall be carburized and hardened alloy steel with the threads ground
after heat treating or rolled with 8 micro-inch finish and heat treated. The worm gear
shall be alloy bronze.
Unit gearing shall be fully lubricated.
Gearing and shafting supported on anti-friction bearings with thrust components
supported by use of tapered roller bearings.
Torque Switches:
Torque switch shall be an electronic sensor, adjustable from 40 to 100% of torque
limit in 1 % increments. The motor shall be de-energized if the torque limits is
exceeded. A boost function shall be included to percent torque trip during initial
valve/gateunseating, a "Jammed Valve" protection feature, with automatic retry
sequence, shall be incorporated to de-energize the motor if no movement occurs.
Manual Operation:
Provide a permanently mounted handwheel or hand crank for manual operation.
Handwheelor hand crank shall not rotate during electric operation, but shall be
responsive to manual operation at all times except when being electrically operated.
Motor shall not rotate during hand operation, nor shall a seized motor prevent manual
operation.
When in manual operating position, the unit shall remain in this position until the
motor is next energized at which time the operator shall automatically return to
electric operation and shall remain in motor position until manual operation is next
desired.
This movement from motor to manual operation shall be accomplished by a positive
declutching lever, which shall disengage the motor and motor gearing mechanically,
not electrically.
It shall not be possible to place the unit inmanual operation when the motor is
running.
Additional Requirements: Refer to various Division 40valve or gate sections or as
shown on the Drawings.
2.3SOURCE QUALITY CONTROL
Actuator Testing: Three (3) types of actuator tests are required; proof-of-design test,
performance test, and pressure test. The as defined by this standard. Actuators shall meet
the requirements for each type of test.
Proof-of-Design Test: Purpose is to prove that the design, material selection, and
manufacture of the actuator are suitable for the purpose intended. One (1) production
sample of each actuator size shall be tested. Should the actuator design be changed or
modified so as to affect its strength of function, the test shall be repeated in accordance
with the requirements of AWWA C540.
Performance Test: Purpose is to prove that each actuator is in working order prior to
shipment. Each actuator and valve assembly shall be cycled a minimum of three (3) times
using the start and stop controls from the fully closed to the fully open position to
demonstrate that the complete assembly, including controls, operates properly.
Pressure Test: Each actuator shall be tested at the overload pressure. The duration of this
test shall be sufficient to allow visual examination for leakage and shall be a minimum of
one (1) minute.
Test Certification: Certification of tests and copies of test or certificate of conformity reports
shall be provided on request if the request is made prior to the time of testing.
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2.4ACTUATOR MOUNTING
Actuator Mounting Responsibility: Actuators shall be shipped to the control valve or gate
supplier’s facility for mounting and assembly on the control valve or gate, calibration, and
acceptance testing. A certification of the calibration, testing, and warranty shall be included
in the final O&M Manual.
Mounting height and position shall be as shown on Drawings.
EXECUTION
3.1INSTALLER
CONTRACTOR
3.2INSTALLATION
CONTRACTOR to install equipment per this Section and the manufacturer’s installation
instructions.
3.3FIELD / SITE QUALITY CONTROL
Manufacturer Services
Manufacturer Field Representative: The Manufacturer Field Representative shall be
present at the project site or classroom designated by OWNER for minimum person-
days and trips provided in the table below. Each person-day shall be defined as
eight(8) hours duration, exclusive of travel. The Manufacturer Field Representative
shall revisit the jobsite as often as necessary to correct deficiencies.
Table 1 –Manufacturer Field Services
No. of Person
Work DescriptionNo. of Trips
Days
Installation Assistance and Inspection11
Acceptance Test and Initial Training21
Post-Startup Training11
3.4SYSTEM STARTUP
Startup of the facility shall be in accordance with Section 01 75 25“Equipment Testing and
Startup.” Installation Assistance and Inspection. After Equipment Installation and before
start up, the CONTRACTOR and Manufacturer Field Representative shall inspect the
installation of the equipment. A preliminary running period (as applicable) will be provided
for the CONTRACTOR to make field adjustments with the Manufacturer Field Representative.
CONTRACTOR shall submit a report for manufacturer approval of equipment installation.
Initial Training. Manufacturer shall perform initial training at the end of the Acceptance Test
for owner’s representative. Training shall be with a draft of the full Operation and
Maintenance Manuals.
Post-Startup Training. Manufacturer will perform additional training at a time mutually
agreeable to the OWNER and manufacturer to take place no earlierthan 30 days after
equipment substantial completion and no later than 90 days after substantial completion.
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3.5ACCEPTANCE TEST
Conduct an acceptance of the assembled control valve or gate and actuator, verifying the
satisfactory operation and performance of each actuator. Each actuator and valve/gate
assembly shall be cycled a minimum of ten (10) times in the field using the start and stop
controls from the fully closed to the fully open position to demonstrate that the complete
assembly, including controls, operates properly. Control valves and fail “closed” valves shall
also be tested under power loss to verify proper closure.
The test shall be conducted in a manner approved by and in the presence of the ENGINEER.
The equipment and piping will be completely checked for leakage, general operation,
vibration, and related factors.
Each actuator must perform in a manner acceptable to the ENGINEER before final
acceptance will be made by the OWNER.
3.6CLOSEOUT ACTIVITIES
A copy of all information from functional tests including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
END OF SECTION
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SECTION 40 05 62
PLUG VALVES
GENERAL
1.1SUMMARY
Section Includesthe following valves:
Eccentric plug valves, 3-inch and smaller.
Eccentric plug valves, 4-inch and larger.
Related Sections:
Drawings and general provisions of the Contract, including General and
Supplementary Conditions and Division1 Specification Sections, apply to this Section.
Refer to Section 40 05 51 “Common Requirements for Process Valves;”
For information regarding submittals; quality assurance; coordination; material
delivery, handling, and storage; projection conditions; generalrequirements;
materialrequirements; installation of valves; field testing; and related work.
1.2SUBMITTALS
Product Data: For each type of valve indicated,include body, seating, and trim materials;
valve design; pressure and temperature classifications; end connections; arrangement;
dimensions; and required clearances. Include list indicating valve and its application.
Include rated capacities; shipping, installed, and operating weights; furnished specialties;
and accessories.
Product Certificates: For each type of valve, from manufacturer.
Compliance with AWWA, ASTM, and ANSI standards including hydrostatic tests,
operational tests and other testing required by the standards.
Operation and Maintenance Data: Provide in accordance with Section 017823“Operation
and Maintenance Data.”
Field Quality Control: Provide field testing and performance reports.
Manufacturer’s Warranty: Provide manufacturer’s warranty for all indicated products.
1.3QUALITY ASSURANCE
Obtain all valves of the same style and type, along with the associated manual operators,
from a single manufacturer.
NSF Compliance: NSF61, “Drinking Water Systems Components –Health Effects” for valve
materials for potable-water service.
Valve manufacturer shall demonstrate a minimum of five years of experience is similar
applications for size of valves furnished. References shall be provided upon request.
Valve supplier shall maintain a complete stock of parts in the state where the Project is
constructed or shall indicate that parts will be delivered upon 48-hour after receipt of
request.
1.4DELIVERY, STORAGE, AND HANDLING
Prepare valves for shipping as follows:
Protect internal parts against rust and corrosion.
Protect threads, flange faces, grooves, and weld ends.
Set ball and plug valves open to minimize exposure of functional surfaces.
Block valves in either closed or open position.
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Use the following precautions during storage:
Maintain valve end protection.
Store valves indoors and maintain at higher than ambient dew-point temperature. If
outdoor storage is necessary, store valves off the ground in watertight enclosures.
Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not
use handwheels or stems as lifting or rigging points.
PRODUCTS
2.1MANUFACTURERS
Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, those listed
for the various valves.
2.2GENERAL
Valve to include operator, actuator, handwheel, chain wheel, extension stem, floor stand,
worm and gear operator, operating nut, chain, wrench, valve boxes, and all accessories and
related equipment for a complete operating systemas required per this Section. Refer to
Drawings for valves requiring limit switches, electric or pneumatic operators, and related
controls.
Comply with the following:
Suitable for intended service. Renewable parts not to be of a lower quality than
specified.
Same size as adjacent piping.
Ends to suit adjacent piping.
Operator sized to operate valve for full range of pressures and velocities.
Open by turning counterclockwise, unless otherwise specified.
Factory mount operator, actuator and accessories.
Obtain all valves and associated manual operators from a single manufacturer.
2.3VALVE DESCRIPTION
Eccentric Plug Valve, 3-inches and Smaller:
Description: Non-lubricated type, drip-tight shut off with pressure in either direction,
cast body, flanged(ANSI B16.1 Class 125 and ANSI B16.5 Class 150) or threaded
ends (NPT requirements of ANSI B1.20.1)for rigid joints and mechanical joints for
buried valves. Design similar to MSSSP-108.
Body:
Cast iron, ASTM A126, Class B, ductile iron ASTM A536, Grade 65-45-12, or
carbon steel, ASTM A216, Grade WCB, with bolted bonnet of same material.
Body receives a coating of corrosion-resistant nickel seat.
Provide a grit seal for upper and lower journal.
Plug:
Plug with upper and lower shaft in a one-piece casting, with round or
rectangular port.
Material: NBRface, ductile iron for cast iron or ductile iron body, forcarbon
steel body plug to be Type316 stainless steel.
Stem Seal:NBR or PTFE.
Body and Bonnet Bearing: Type 316L stainless steel.
Bonnet Screws and Nuts: Stainless steel.
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Port Area: 100% of connecting pipe area.
Pressure Ratings:
Cast iron:175-psi CWP
Ductile iron:175-psi CWP
Carbon Steel:285-psi CWP
Manufacture and Product:
DeZurik
Pratt
Val-Matic
Eccentric Plug Valve, 4-inches and Larger:
Description: Non-lubricated type, drip-tight shut off with pressure in either direction,
cast body, flanged (ANSI B16.1 Class 125 and ANSI B16.5 Class 150) for rigid joints
and mechanical joints for buried valves. Design similar to MSSSP-108.
Body:
Cast iron, ASTM A126, Class B, or ductile iron, ASTM A536, Grade 65-45-12,
with bolted bonnet of same material.
Body receives a welded overlayof corrosion-resistant nickel seatmachined to a
smooth finish
Plug:
Plug with upper and lower shaft in a one-piece casting, with round or
rectangular port.
Material: Ductile ironwith resilient facing of NBR.
Body and Bonnet Bearing: Type 316L or Type 316 stainless steel.
Packing:NBR or PTFE V-Type.
Bonnet Screws and Nuts: Stainless steel.
Port Area: 100% of connecting pipe area valves 4-inches and smaller, 85% on 16-
inch and smaller, 80% on 18-inch through 24-inch, 75% on 30-inch and larger.
Pressure Ratings:
4-inch to 12-inch: 175-psi CWP
14-inch and Larger: 150-psi CWP
Manufacture and Product:
DeZurik
Pratt
Val-Matic
GAIndustries
2.4OPERATORS
Buried Service:
3-inch and Larger(not installed in Valve Vault):
Non-rising stem withstainless steel shaft extension and wrench nut. Minimum
extension stem diameter shall be 1-inch or diameter of valve shaft, whichever
is larger.
Provide valve box, bonnet and cover.
Above Ground Service:
4-inch and Smaller:Lever
6-inches and Larger: Totally enclosed, geared, manual operator with hand wheel,
wrench nut, or chain wheel as required.
Chain Wheel Operator: Provide for valves having a centerline six feet or more above
the floor, unless otherwise noted.
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Wrench nut, handwheel and gear operator shall comply with the requirements of Section40
05 51 “Common Requirements for Process Valves.”
Electric and pneumatic operators and actuators shall comply with the requirements ofthe
applicableSection 40 05 57.23“Electric Motor Actuators.”
2.5ACCESSORIES
Identification: Provide valve identificationtags in accordance with Section 10 90 00
“Identification, Stenciling, and Tagging.”
Refer to Section 40 05 51 “Common Requirements for Process Valves” for addition
accessories requirements.
EXECUTION
3.1INSTALLATION
Refer to Section 40 05 51 “Common Requirements for Process Valves”for Execution
requirements for the installation, field quality control, and manufacturer’s services.
Plug valves shall be installed with stem installed horizontal.
Install plug valves with flow against face of plug.
Installvalve laying on its side so plug rotates 90-degrees upward to open.
3.2VALVESCHEDULE
Refer to the Drawings for the Valve Schedule. The Valve Schedule is not guaranteed to be
accurate, and list valves 6-inch and larger, unless it is a motor actuated valve. Refer to
Drawings for type, end connections, and locations for all valves.
END OF SECTION
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SECTION 40 05 64
BUTTERFLY VALVES
GENERAL
1.1SUMMARY
Section includesthe following butterfly valves:
AWWA Rubber-Seated Butterfly Valves; 3-inch and larger.
Related Sections:
Drawings and general provisionsof the Contract, including General and
Supplementary Conditions and Division1 Specification Sections, apply to this Section.
Refer to Section 40 05 51“Common Requirements for Process Valves;”
For information regarding submittals; quality assurance; coordination; material
delivery, handling, and storage; projection conditions; general requirements;
material requirements; installation of valves; field testing; and related work.
1.2SUBMITTALS
Product Data: For each type of valve indicated,include body, seating, and trim materials;
valve design; pressure and temperature classifications; end connections; arrangement;
dimensions; and required clearances. Include list indicating valve and its application.
Include rated capacities; shipping, installed, and operating weights; furnished specialties;
and accessories.
Product Certificates: For each type of valve, from manufacturer.
Compliance with AWWA, ASTM, and ANSI standards including hydrostatic tests,
operational tests and other testing required by the standards.
Operation and Maintenance Data: Provide in accordance with Section 017823“Operation
and Maintenance Data.”
Field Quality Control: Provide field testing and performance reports.
Manufacturer’s Warranty: Provide manufacturer’s warranty for all indicated products.
1.3QUALITY ASSURANCE
Obtain all valves of the same style and type, along with the associated manual operators,
from a single manufacturer.
NSF Compliance: NSF61, “Drinking Water Systems Components –Health Effects” for valve
materials for potable-water service.
Valve manufacturer shall demonstrate a minimum of five years of experience is similar
applications for size of valves furnished. References shall be provided upon request.
Valve supplier shall maintain a complete stock of partsin the state where the Project is
constructed or shall indicate that parts will be delivered upon 48-hour after receipt of
request.
1.4DELIVERY, STORAGE, AND HANDLING
Prepare valves for shipping as follows:
Protect internal parts against rust and corrosion.
Protect threads, flange faces, grooves, and weld ends.
Set butterfly valves closed or slightly open.
Block valves in either closed or open position.
Use the following precautions during storage:
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Maintain valve end protection.
Store valves indoors and maintain at higher than ambient dew-point temperature. If
outdoor storage is necessary, store valves off the ground in watertight enclosures.
Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not
use handwheels or stems as lifting or rigging points.
1.5REFERENCES
Referenced Standards: Rubber seated shall be tight closing type conforming to the latest
version of AWWA C504 standards.
AWWA C-540 -"Power-Activating Devices for Valves and Sluice Gates."
AWWA C-550 -"Standard Specification for Protective Interior Coatings for Valves and
Hydrants."
ASTM A-48 -"Standard Specification for Grey Iron Castings."
ASTM A-126 -"Standard Specification for Grey Iron Castings for Valves, Flanges, and
Pipe Fittings."
ASTM A-536 -"Standard Specification for Ductile Iron Castings."
ANSI -"American National Standards Institute."
ANSI/NSF -"Standard 60/61."
1.6QUALITY ASSURANCE
Each valve shall have manufacturer's nameplate in stainless steel showing the pressure
ratings, serial and model numbers, year manufactured and other pertinent data.
Butterfly valves and manual operators shall be completely assembled at the factory,
adjusted for correct seating, and tested in accordance with the AWWAC-504 standard.
Factory adjustments and operational tests shall be performed on each valve with the valve
oriented in the same position as the installed field position. The valves shall be cycled five
times (full open to full close) and successfully seat tested each cycle to certify proper
seating. Seat adjustments and manual indicators shall be set and checked at the factory.
For valves 24 inches and larger, the manufacturer shall conduct ultra-sound testing on each
of the valve bodies and discs in addition to hydrostatic testing of each valve body. The
manufacturer shall perform the hydrostatic valve tests in accordance with AWWAC-504 and
provide certified reports of test results. The manufacturer shall notify the OWNER three
weeks prior to testing so that the OWNER may witness tests. Hydrostatic test pressures
shall be 150 psi for the bodies and 150psi for the discs and seats.
All surfaces and materials in contact with water, or in contact with a chemical being added
to water that is being treated for potable use, shall conform to ANSI/NSF61 and be certified
by an organization accredited by ANSI, or shall meet the TCEQ requirements for contact
with potable water.
PRODUCTS
2.1MANUFACTURERS
Crispin, K-Flo
DeZurik
Pratt
2.2GENERAL
Obtain all butterfly valves and associated manual operators of a given type from a single
manufacturer.
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Valve operators to turn to left, counterclockwise, to open;and to right, clockwise, to close.
All valves shall have position indicators.
End connections to be compatible with those specified for pipe. Mechanical joints shall
conform to ANSI/AWWA C11/A21.11. Flanges shall conform to ANSI B16.1 and have a
pressure rating to meet the requirements of the adjoining pipe.
Furnish geared operators for all valves in pressure piping systems (10psigworking
pressure) and valves 6inches and larger, unless otherwise specified.
Furnish geared operators with the following features unless otherwise specified.
Weatherproof enclosure.
Grease lubricated design.
Closes valve when turned clockwise.
Position indicator.
All internal materials for valves shall withstand corrosion.
All valves in submerged service shall utilize 316 stainless steel hardware and bolts.
The water being delivered through the valves may be treated with chlorine and/or
chloramines. The materials used to manufacturethe valves shall be resistant to chlorine
and chloramine oxidation.
Buried valves shall be quarter-turn butterfly valves that utilize 316 stainless steel shaft
extensions with stem guides or rock shields, 2-inch square nut, and adjustable valve boxes
with covers. A 2-inch nut shall be located within 18 inches of grade.
Fasteners on buried valves, valves in manholes and vaults, MJjoints, flanges, and restraints
shall be 316stainless steel. Buried MJ fitting bolts may be Corten. Fasteners on exposed
valves shall be 316 stainless steel.
Areas on the disc and body that are subject to cavitation damage shall be constructed of
materials that are resistant to the effects of cavitation.
Maximum velocity through the valves should be assumed to be 12 feet per secondwhen
fully opened.
2.3VALVE DESCRIPTION
Provide valves as shown on the Plans.
Valve type: AWWA C504 rubber-seated butterfly valve.
Non-shock working pressure: 150 psi, minimum, sized to meet test pressure of pipeline:
Body type: Short body flanged, unless shown otherwise on the plans.
Valve flanges for valves 24-inch and larger and for all exposed valves shall have ANSI
Class125or Class 250 flanges based on the corresponding pipe class. Buried valves
smaller than 24-inch shall utilize MJ joints. Two (2) trunnions for shaft bearings shall
be integral with each valve body. Valve bodies shall be hydrostatic tested to a
minimum of working pressure class.
Valve construction:
Body: Cast iron (ASTM A126 Class B)or ductile iron(ASTM A-536 Grade 65/45/12) for
valves smaller than 24-inch diameter. Ductile iron(ASTM A-536 Grade 65/45/12)for
valves 24inches and larger.
Shaft: Solid stainless steel, type 316.
Disc: Ductile iron ASTM A-536, Grade 65/45/12. Operating pressure of valve disc
shall be 150psi. Valve discs shall be hydrostatic tested to a minimum of 150psi.
Seats: EPDM rubber mechanically secured to the body. Valve seats shall provide tight
shut-off at 0 to 150psi operating pressure. The seat shall be field adjustable and
field replaceable. The mating surface shall be 18-8 stainless steel or a 95percent
pure nickel overlay.
Bearings: Fitted sleeve type. Bearings shall be corrosion resistant and self-lubricated
materials that will not deteriorate neutral or synthetic rubber.
PLUMMER ASSOCIATES, INC.40 05 64-PAGE 3OF 4BIDSET
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Shaft Seals: Split-V or O-ring type, suitable for buried service requiring no gland
adjustment.
2.4OPERATORS
Refer to Section 40 05 51“Common Requirements for Process Valves” for manual operators
requirements.
Refer to Section 40 05 57.23“Electric Motor Operators” for electric motor operator
requirements.
2.5FINISHES
Paint exterior of valves and operators as shown on the plans and specified in Section 40 05
51 “Common Requirements for Process Valves,”colors to be selected by OWNER. Interior
of valves shall be factory lined with NSF approved epoxy meeting the requirements of
Section 09 91 00“Painting and Protective Coatings”,AWWA C550, and Section 40 05 51
“Common Requirements for Process Valves.”Flange faces shall be protected from
atmospheric corrosion.
EXECUTION
3.1INSTALLATION
Refer to Section 40 05 51 “Common Requirements for Process Valves”for Execution
requirements for the installation, field quality control, and manufacturer’s services.
Install butterfly valves with shafts horizontal unless otherwise shown.
END OF SECTION
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SECTION 40 05 64.43
FIBERGLASSDAMPERS
GENERAL
1.1SUMMARY
Section Includes:
Equipment furnished and installed under this section shall be fabricated, assembled,
erected, and placed in proper operating condition in full conformity with drawings,
specifications, engineering unless exceptions are noted by the ENGINEER.
Equipment furnished under this section shall be coordinated with other components of
the applicable odor control systems.
The dampers will be installed to isolate equipment and balance air flows. The air flow
through the odor control dampers will consist of malodorous air fully saturated with
water vapor and containing an estimated maximum of 1,500ppmhydrogen sulfide
and dilute sulfuric acid condensate.
Related Sections:
Drawings and general provisions of the Contract, including General and
Supplementary Conditions and Division1 Specification Sections, apply to this Section.
Section 099100“Paintingand Protective Coatings.”
Section 10 90 00“Identification, Stenciling, and Tagging.”
Section 4005 36.13 “Foul Air Fiberglass Ductwork.”
Section 40 05 05 “Piping System, Basic Materialsand Methods.”
Section 40 05 07“Hangers and Supports for Piping Systems.”
Section 44 31 83“Foul Air Collection System Testing, Adjusting, and Balancing.”
1.2REFERENCES(NOT USED)
1.3QUALITY ASSURANCE
Manufacturer Qualifications: Manufacturer shall demonstrate a minimum of five (5) years of
experience in similar applications for size of odor controlduct system furnished. References
shall be provided upon request.
Single Manufacturer: Duct dampers of each type shall be the product of a single
manufacturer.
Each damper and control valve shall be designed for the following conditions:
Air Temperature, °F:0-125
Design pressure, psi:25
Design vacuum,inches water column:30
Where indicated in the Drawings and this Section, all Type 316 stainless steel materials shallWhere indicated in the Drawings and this Section, all Type 316 stainless steel materials
shallWhere indicated in the Drawings and this Section, all Type 316 stainless steel materials shallWhere indicated in the Drawings and this Section, all Type 316 stainless steel materials
shallWhere indicated in the Drawings and this Section, all Type 316 stainless steel materials shallWhere indicated in the Drawings and this Section, all Type 316 stainless steel materials
shall
include the following componentsinclude the following componentsinclude the following components:
Molybdenum: 2 –3%
Chromium: 16 –18%
Nickel: 10 –14%
1.4SUBMITTALS
Drawings and Data: Complete fabrication, assembly, and installation drawings, together
with detailed specifications and data covering materials used, parts, devices, and other
accessories forming a part of the equipment furnished, shall be submitted in accordance
with the submittals section. The data shall include, but not be limited to, the following:
PLUMMER ASSOCIATES, INC.40 05 64.43-PAGE 1OF 6BIDSET
0537-038-01 FIBERGLASS DAMPERS JANUARY2023
Name of manufacturer.
Type and model.
Materials of construction.
Pressure rating.
Vacuum rating.
Overall dimensions.
Connection size.
Total weight, including actuator.
AMCA approved leakage test.
Position image indicator for each size.
Manufacturer’s warrantyfor each product indicated.
1.5DELIVERY, STORAGE, AND HANDLING
Protection: Protect dampers, accessories, and purchased products from damage during
shipping, storage and handling as recommended by the Manufacturer. Prevent end damage
and prevent dirt and moisture from entering.
Storage: Where possible, store dampers inside and protect from weather. Where necessary
to store outside, store above grade and enclose with waterproof wrapping as recommended
by the Manufacturer.
PRODUCTS
2.1MANUAL BALANCINGDAMPER
Dampers, unless otherwise indicated,shall be of the single-blade type complete with
channel-type frame, close fitting blade, full-length axle, and bearings. The damper shall be
constructed of fiberglass reinforced plastic using a vinyl ester resin and shall have the same
inside dimensions as the connecting piping. All fiberglass reinforced plastic fabrications shall
have a flame spread of 25 or less when tested in accordance with ASTME84. The axles
shall be not less than 3/4-inch in diameter and shall be continuous through the damper.
Unless noted otherwise on the plans, dampers shall be installed with flanged connections.
Dampers using slip-on connections in any manner are not acceptable.
Dampers denoted for balancing service shall be equipped with a blade stop. Dampers
denoted for isolation service shall be equipped with replaceable-type full-circumference
blade edge seal, angle type blade stop, and shaft seal.
Dampers shall have a minimum pressure rating of 30inches water column. Isolation
dampers shall have maximum leakage rate of three (3)cubic feet per minute per square
foot of damper area at minimum pressure rating. Current AMCA leakage and flow loss tests
shall be furnished as part of the submittal.
Materials
Frame: Fiberglass reinforced plastic with vinyl ester resin.
Blade: Fiberglass reinforced plastic with stiffeners as required.
Axle/Shaft: Type 316 stainless steelor continuous fiberglass reinforced plastic rod
with stiffeners as required, 6-inch extension beyond frame stiffeners as required.
Bearings: Molded Teflon.
Blade Stop: Fiberglass reinforced plastic bar or angle.
Blade Seal: Neoprene or EPDM
Shaft Seal: Neoprene or EPDM
Flanges: Flanges shall comply with PS15-69 Table5at design pressure of 25 psi, and
have a minimum of ANSI/ASME B16.1, Class 25 diameter drilling. Coordinate drilling
pattern with connecting pipe or duct.
Manufacturer: Provide products of one of the following:
PLUMMER ASSOCIATES, INC.40 05 64.43-PAGE 2OF 6BIDSET
0537-038-01 FIBERGLASS DAMPERS JANUARY2023
Belco Manufacturing
Daniel Mechanical
Engineered Composite Systems
Greenheck
Swartwout "Model 912"
Approved equivalent.
Rating Conditions
Velocity through Damper: 4,000 fpm.
Pressure Rating: 30-in water column.
Allowable Leakage: With a differential pressure of 12-in wg.
Size Maximum Allowable
(in Diameter) Leakage (cfm)
72 200
66 186
60 172
54 158
42 130
36 50
24 25
18 20
One damper of each size shall be shop tested at 12-in wg differential and shall meet
the above leakage. Submit damper test report to the ENGINEER. Damper shall not be
shipped until approved by the Engineer.
2.2BUBBLE-TIGHT DAMPERSAND ISOLATION DAMPERS
Furnish and install where indicated on the Drawings manually operated butterfly or parallel
blade dampers, with handle for manual operation and positive locking quadrant for
balancing purposes.
Dampers shall have flanged connections and fabricated from materials specified herein.
Dampers using slip-on connections in any manner are not acceptable.
Locking quadrants shall have a positive method of holding the damper in its selected
position, such as a bolt through both the quadrant and the lever arm. Systems using springs
or other devices that can vibrate loose are not acceptable.
Rating Conditions
Velocity through Damper: 4,000 fpm.
Pressure Rating: 30-in water column.
Materials
Bearings: Teflon.
Blade: FRP, angle reinforced.
Frame: FRP.
Axles/Shafts: Type 316 stainless steel, full length of damper size as shown on the
Drawings.
Finish: FRP.
Handle: Type 316 stainless steel, or FRP.
Pins: Type 316 stainless steel.
Blade Stops: FRP angles with elastomer seals suitable for use at the design
conditions.
Bushings: Teflon.
Hardware: Type 316 stainless steel.
Angles: FRP.
PLUMMER ASSOCIATES, INC.40 05 64.43 - PAGE 3 OF 6 BID SET
0537-038-01 FIBERGLASS DAMPERS JANUARY 2023
Dimensions: As detailed on the Drawings
Manufacturer: Provide products of one of the following.
Belco Manufacturing
Greenheck
Engineered Composite Systems
Daniel Mechanical
Approved Equivalent
2.3PRESSURE RELIEF DAMPERSPRESSURE RELIEF DAMPERSPRESSURE RELIEF DAMPERSPRESSURE RELIEF DAMPERSPRESSURE RELIEF DAMPERS
Pressure relief dampers shall be installed where indicated on the Drawings. Dampers shall
be either parallel blade or butterfly type.The dimensions of each damper shall be as shown
on the Drawings.
Dampers shall operate by allowing airto flow only from the pressurized system to the
atmosphere. Dampers permitting airflow in both directions shall not be allowed.
Dampers shall have flanged connections. Slip-on connections are not permissible.
A counterbalance system shall be included to allow for manual operationand adjustmentof
the damper.
Rating Conditions:
o
Maximum Temperature: 180F.
Maximum Differential Pressure: 2 inches water column.
Maximum Velocity: 2,000 fpm.
Start-to-Open Pressure: 0.05 inches water column.
Dampers shall be constructed from the follow materials:
Frame: Type 316 stainless steel.
Blade: Type 316 stainless steel, minimum of 0.039inches thick.
Blade Seal: Thermoplastic elastomer (TPE).
Axle: Type 316 stainlesssteel.
Axle Bearings: Type 316 stainless steel with acetal races.
Linkage Material: Type 316 stainless steel.
Jamb Seal: EPDM.
Manufacturer: Provide products of one of the following.
Greenheck
Approved equal
2.4VACUUM RELIEF DAMPERSVACUUM RELIEF DAMPERSVACUUM RELIEF DAMPERSVACUUM RELIEF DAMPERSVACUUM RELIEF DAMPERS
Vacuum relief dampers shall be installed where indicated on the Drawings. Dampers shall be
either parallel blade or butterfly type.The dimensions of each damper shall be as shown on
the Drawings.
Dampers shall operate by allowing air to flow only from the atmospheretothe pressurized
system. Dampers permitting airflow in both directions shall not be allowed.
Dampers shall have flanged connections. Slip-on connections are not permissible.
A counterbalance system shall be included to allow for manual operation and adjustment of
the damper.
Rating Conditions:
o
Maximum Temperature: 180F.
Maximum Differential Pressure: 2 inches water column.
Maximum Velocity: 2,000 fpm.
Start-to-Open Pressure: 0.05 inches water column.
Dampers shall be constructed from the follow materials:
PLUMMER ASSOCIATES, INC.40 05 64.43-PAGE 4OF 6BIDSET
0537-038-01 FIBERGLASS DAMPERS JANUARY2023
Frame: Type 316 stainless steel.
Blade: Type 316 stainless steel, minimum of 0.039inches thick.
Blade Seal: Thermoplastic elastomer (TPE).
Axle: Type 316 stainless steel.
Axle Bearings: Type 316 stainless steel with acetal races.
Linkage Material: Type 316 stainless steel.
Jamb Seal: EPDM.
Manufacturer: Provide products of one of the following.
Greenheck
Approved equal
2.5OPERATORS
Damper actuators shall be furnished and installed as indicated in the schedules. All required
linkages and accessories required for a complete installation shall be furnished.
Hand Operators: Each hand operator shall have a locking quadrant suitable for positioning
the blade at any intermediate position. Any metallic components shall be Type 316 stainless
steel.
Dampers 24” in diameter or larger shall be supplied with a worm gear operator.
Dampers installed 6 feet above finished floor or higher shall be supplied with a chain wheel
operator. Chains shall be restrained in outdoor installations to prevent damage to
surrounding equipment.
Position indicator plates will be marked 0 to 100% in 10% increments. Pointers will be
readable to 5% minimum. Position indicators shall be Type 316stainless steelor FRP.
2.6SPARE PARTS
The following spare parts shall be furnished for each size and type of damper:
Item Quantity
Flat Flange Gaskets 2 each
Shaft Seals 2 each
Blade Seal 2 each
Position Indicator Plate One per damper installed
Spare parts shall be suitably packaged in accordance with the General Equipment
Stipulations, with labels indicating the contents of each package and equipment number
designated. Spare parts shall be delivered to the OWNER as directed.
EXECUTION
3.1INSTALLATION
The dampers shall be positioned to fit on the connecting piping. Unless otherwise necessary
for proper operation of the damper, the axles shall be installed in the horizontal position.
The inside of the dampers shall be smooth, clean, and free from blisters and dirt when
installed. Dampers forisolation service shall be installed with the shaft side of the damper
on the pressure side (or toward the equipment isolated).
END OF SECTION
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SECTION 40 05 91
COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT
PART 1 - GENERAL
1.1!SUMMARY
A.!Where specified in the equipment manufacturer's specification, the equipment
manufacturer's shall furnish a fully functional industrial control panels to manually and
automatically operate equipment as specified in the detailed requirements of the equipment
sections of Division 40s, and supplemented with logic and schematics diagrams as shown on
the Electrical and Instrumentation Drawings.
B.!It is the intent of these specifications to have all starters, VFDs, breakers, control panel
devices relays, PLC if required and signal conditioning components included within their
respective control panels. The equipment supplier shall be responsible for final sizing of
enclosures to meet the clearance requirements of NFPA 70 and NFPA 79 and as specified
herein. Should the equipment supplier submit a panel size and layout that is, in the opinion
of the OWNER or the ENGINEER, insufficient in size to meet these requirements, the
submittal will not be approved and will be returned for revision and resubmission. The
equipment supplier shall be required to revise the panel size and layout and resubmit for
approval at no additional cost to the OWNER.
C.!All enclosures and panel components shall be of the same manufacture wherever possible.
D.!Installation and configuration of network infrastructure cabling and equipment shall be a
cooperative and coordinated effort between OWNER, the CONTRACTOR, and the Control
System Integrator. The Equipment Supplier and the Control System Integrator shall furnish
all labor necessary for the installation and testing as required to fully meet the applicable
specifications of the Contract Documents.
E.!All equipment, field devices and instruments shall utilize tags names as shown on Contract
Documents.
F.!All Industrial Control Panels shall have a UL 508A label affix to the inside of the panel. Those
panels with equipment or instrumentation is Class I, Division I areas shall also comply with
UL 698.
G.!Related Sections include but are not necessarily limited to:
1.!Division 00 - Procurement and Contracting Requirements.
2.!Division 01 - General Requirements.
1.2!REFERENCES (NOT USED)
1.3!ADMINISTRATIVE REQUIREMENTS (NOT USED)
1.4!SUBMITTALS
A.!Comply with the submittal requirements of Section 01 30 00 "Administrative Requirements",
Individual Equipment Specifications, and as described below.
B.!Product Data: For each type of product indicated, include construction details, material
descriptions, dimensions of individual components and profiles, rated capacities, operating
characteristics, electrical characteristics, and furnished specialties and accessories.
C.!Panel Layout Drawings and Wiring Diagrams Submittal
1.!Panel Layout Drawings: Drawings shall be furnished for all panels, consoles, and
equipment enclosures specified. Panel assembly and elevation drawings shall be
drawn to scale and detail all equipment in or on the panel. Panel drawings shall be
11x17 inches in size. At a minimum, the panel drawings shall include the following:
PLUMMER ASSOCIATES, INC. 40 05 91 - PAGE 1 OF 23 BID SET
0537-038-01 COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
a.!Interior and exterior panel elevation drawings to scale.
b.!Nameplate schedule.
c.!Conduit access locations.
d.!Panel construction details.
e.!Cabinet assembly and layout drawings to scale. The assembly drawing shall
include a bill of material on the drawing with each panel component clearly
defined. The bill of material shall be cross-referenced to the assembly drawing
so that a non-technical person can readily identify any component of the
assembly by manufacturer and model number.
f.!Fabrication and painting specifications including color (or color samples).
g.!Construction details, NEMA ratings, intrinsically safe barrier information, gas
sealing recommendations, purging system details, etc. for panels located in
hazardous locations or interfacing to equipment located in hazardous areas.
h.!For every control panel, heating and cooling calculations for each panel
supplied indicating conformance with cooling requirements of the supplied
equipment and environmental conditions. Calculations shall include the
recommended type of equipment required for both heating and cooling.
i.!Submit evidence that all control panels shall be constructed in conformance
with UL 508 and bear the UL seal confirming the construction. Specify if UL
compliance and seal application shall be accomplished at the fabrication
location or by field inspection by UL inspectors. All costs associated with
obtaining the UL seal and any inspections shall be borne by the Control System
Integrator.
2.!Panel Wiring Diagrams: Panel wiring diagrams depicting wiring within and on the
panel as well as connections to external devices. If Loop Wiring Diagrams are
specified below, equipment external to the control panel and related external
connections do not need to be shown on the Panel Wiring Diagrams. Panel wiring
diagrams shall include power and signal connections, UPS and normal power sources,
all panel ancillary equipment, protective devices, wiring and wire numbers, and
terminal blocks and numbering. Field device wiring shall include the device tag and a
unique numeric identifier. The diagrams shall identify all device terminal points that
the system connects to, including terminal points where I/O wiring lands on
equipment not supplied by the equipment supplier. Wiring labeling used on the
drawings shall match that shown on the Contract Documents. I/O wiring shall be
numbered with rack number, slot number, and point number. Two-wire and four-wire
equipment shall be clearly identified and power sources noted. Submit final wire
numbering scheme. Panel drawings shall be 11x17 inches in size.
3.!ISA Loop Wiring Diagrams: Individual wiring diagram for each field device or
instrument shall be required. Loop diagrams shall comply with the minimum
requirements of ISA S5 4. Drawings shall be 11x17-inch sheets for each device.
Divide loop diagram into areas for panel face, back-of-panel, and field. Show the
terminal numbers, location of dc power supply, switching contacts in analog loops and
output contacts of analog devices. Show circuit and raceway schedule names and
terminal numbers. Drawings shall show electrical connections between equipment,
consoles, panels, terminal junction boxes, and field mounted instruments. Component
and panel terminal board identification numbers and external wire and cable numbers
shall be shown. Circuit names shall match Circuit and Raceway Schedule.
Intermediate terminations between field elements and panels to terminal junction
boxes and pull boxes shall be shown. Diagrams shall bear Subcontractor signature
attesting diagrams have been coordinated with electrical drawings.
PLUMMER ASSOCIATES, INC. 40 05 91 - PAGE 2 OF 23 BID SET
0537-038-01 COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
D.!Memory Map: Submit memory map of PLC or Controller registers to be transmitted to Plant
Control System.
E.!Operation and Maintenance Data: For control panels, installed devices, and components to
include in emergency, operation, and maintenance manuals. In addition to items specified in
Section 01 78 23 "Operation and Maintenance Data", include the following:
F.!Routine maintenance requirements for control panels and all installed components.
G.!Manufacturer's written instructions for testing and adjusting overcurrent protective devices.
H.!Final As-
feature, for use by the OWNER in modifying panels for future expansion or required
modifications.
I.!Load-Current and Overload-Relay Heater List: Compile after motors have been installed and
arrange to demonstrate that selection of heaters suits actual motor nameplate full-load
currents.
J.!Load-Current and List of Settings of Adjustable Overload Relays: Compile after motors have
been installed and arrange to demonstrate that dip switch settings for motor running
overload protection suit actual motor to be protected.
K.!Configuration Settings: Compile after panel has been installed and tested, all configuration
or program settings, of VFDs, meters, controllers, timers, etc. in documentation format.
1.5!QUALITY ASSURANCE
A.!The manufacturer of the control panels shall have produced similar equipment for a
minimum period of five years. When requested by the ENGINEER, an acceptable list of
installations with similar equipment shall be provided demonstrating compliance with this
requirement.
B.!The control panels shall be assembled in a UL 508 certified facility. A submittal of
documentation certifying that the panel fabrication facility is a UL 508 certified facility is
required.
C.!All components and material shall be new and of the latest field proven design and in
current production. Obsolete components or components scheduled for immediate
discontinuation shall not be used.
D.!Control panels submitted shall fit within the space shown on the Drawings. Equipment which
does not fit within the space is not acceptable.
1.6!DELIVERY, STORAGE, AND HANDLING
A.!Completed industrial control panels and related equipment shall be handled and stored in
accordance with manufacturer's instructions. Two copies of these instructions shall be
included with the equipment at the time of shipment, and shall be made available to the
general CONTRACTOR, the OWNER, and ENGINEER.
B.!Shipping groups shall be designed to be shipped by truck, rail, or ship. Indoor groups shall
be bolted to skids. Accessories shall be packaged and shipped with each panel.
C.!Visible shipping damage to any portion of a shipment shall be assumed to have also
damaged the surrounding portion. The visibly damaged and the surrounding panels shall be
returned to the manufacture's UL 508 facility for examination and damaged equipment
replaced.
D.!Industrial Control Panels shall be installed in their permanent finished location shown on the
drawings within 7 calendar days of arriving onsite. If the equipment cannot be installed
within 7 calendar days, the equipment shall not be delivered to the site, but stored offsite,
y for permanent
installation of the equipment or within ENGINEER-approved on-site storage facilities.
PLUMMER ASSOCIATES, INC. 40 05 91 - PAGE 3 OF 23 BID SET
0537-038-01 COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
E.!Space heaters shall be furnished in industrial control panels and the CONTRACTOR shall
provide temporary electrical power and operate space heaters during storage, and after
equipment is installed in permanent location, until equipment is placed in service.
1.7!SITE CONDITIONS (NOT USED)
1.8!WARRANTY
A.!
equipment warranty.
B.!All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
PART 2 - PRODUCTS
2.1!RATINGS
A.!The service voltage shall be as specified and as shown on the Drawings. The overall short
circuit withstand and interrupting rating of the equipment and devices shall be equal to or
greater than the overall short circuit withstand and interrupting rating of the feeder device
immediately upstream of the Control Panel, but not less than 22,000 Amps rms symmetrical
at 480/277 Vac, 480 Vac or 120 Volts per equipment specifications. This includes all circuit
breakers and combination motor starters. Systems of motor controllers employing series
connected ratings for main and feeder devices shall not be used. Motor starter units shall be
tested and UL 508A labeled for the specified short circuit duty in combination with the motor
branch circuit protective device.
B.!There shall be selective device coordination between the Main Breaker, Feeder Breakers and
control circuit protective devices. When using a circuit breaker or fuses as a main protective
device, the instantaneous trip levels of the main protective device shall be higher than the
available fault current to the control panel. If fuses are utilized in the control panel design,
the protective devices for 3-phase loads shall contain single phase protection of such
equipment. If a fault occurs in the circuit of one load of a design with a backup load, the
feeder protective device shall not remove both loads from the control system.
C.!Use ground fault sensing on grounded wye systems.
D.!The complete control panel assembly shall be UL-certified or carry a UL listing for "Industrial
Control Panels".
E.!The control panel shall meet all applicable requirements of the National Electrical Code.
F.!The control panel enclosure shall be NEMA rated as specified herein.
G.!Motor controllers, including associated devices, shall be designed for continuous operation at
rated current in a 40°C ambient temperature.
H.!For additional ratings and construction notes, refer to the mechanical equipment
specifications and the Drawings.
I.!The manufacturer shall produce and install on each panel, an Arc Flash Warning Label listing
the various Flash Hazard Protection Boundaries, calculated from NFPA 70E, Annexes, as
listed below:
1.!Flash Hazard Protection Boundary.
2.!Limited Approach Boundary.
3.!Restricted Boundary.
4.!Prohibited Boundary.
5.!Incident Energy Level.
PLUMMER ASSOCIATES, INC. 40 05 91 - PAGE 4 OF 23 BID SET
0537-038-01 COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
6.!Required Personal Protective Equipment Class.
7.!Type of Fire Rated Clothing.
J.!Provide an Arc Flash Warning Label, printed in color and affixed to the front of each panel
provided. Size of each label shall be not less than 8 inches wide and 6 inches tall.
2.2!MANUFACTURERS
A.!Subject to compliance with requirements, available manufacturers offering products that
may be incorporated into the Work include, but are not limited to, have been named within
the various paragraphs of this Section.
B.!The listing of specific manufacturers within the various paragraphs of this Section does not
imply acceptance of their products that do not meet the specified ratings, features and
functions. Manufacturers listed within the various paragraphs of this Section are not relieved
from meeting these specifications in their entirety.
2.3!GENERAL REQUIREMENTS
A.!Ensure that final enclosure sizing and panel arrangements accommodate all required
equipment for a fully integrated and operational system as specified herein and in the
Contract Documents.
B.!The devices designated for rear-of-panel mounting shall be arranged within the panel in a
manner to allow for ease of maintenance and adjustment. Heat generating devices such as
power supplies shall be located at or near the top of the panel.
C.!All components shall be mounted in a manner that shall permit servicing, adjustment,
testing, and removal without disconnecting, moving, or removing any other component.
Components mounted on the inside of panels shall be mounted on removable plates and not
directly to the enclosure. Mounting shall be rigid and stable unless shock mounting is
required otherwise by the manufacturer to protect equipment from vibration. Component
mounting shall be oriented in accordance with manufacturer's recommendations. The
internal components shall be identified with suitable plastic or metal engraved nametags
mounted adjacent to (not on) each component identifying the component in accordance
with the drawing, specifications, and equipment supplier's data.
D.!All exterior panel mounted equipment shall be installed with suitable gaskets, faceplates,
etc. required to maintain the NEMA rating of the panel.
E.!All panel doors shall have a lock installed in the door handle, or a hasp and staple for
padlocking. Locks for all panels provided under this Contract shall be keyed alike.
F.!Nameplates
1.!All panels and panel devices shall be supplied with suitable nameplates which identify
the panel and individual devices as required. Unless otherwise indicated, each device
nameplate shall include up to 3 lines with the first line containing the device tag
number as shown on the drawings, the second line containing a functional description
(e.g., Recirculation Pump No. 1), and the third line containing a functional control
description (e.g., Start).
2.!Unless escutcheon plates are specified or unless otherwise noted on the Drawings,
nameplates shall be 3/32-inch thick, black and white, Lamicoid with engraved
inscriptions. The letters shall be Black against a White background unless otherwise
noted. Edges of the nameplates shall be beveled and smooth. Nameplates with
chipped or rough edges will not be acceptable.
3.!Nameplate fasteners and mounting shall be epoxy adhesive or stainless-steel screws
for cabinet mounted nameplates
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4.!For every panel, provide a panel nameplate with a minimum of 1-inch high letters.
Provide legend plates or 1x3-inch engraved nameplates with 1/4-inch lettering for
identification of door mounted control devices, pilot lights, and meters.
5.!Single lamicoid nameplates with multiple legends shall be used for grouping of
devices such as selector switches and pilot lights that relate to one function.
2.4!PANEL REQUIREMENTS
A.!Structure and Enclosure
1.!Panels shall be of continuous welded-steel construction. Provide angle stiffeners as
required on the back of the panel face to prevent panel deflection under instrument
loading or operation. Internally the panels shall be supplied with a structural
framework for instrument support purposes and panel bracing. The internal
framework shall permit panel lifting without racking or distortion. Provide removable
lifting rings designed to facilitate simple, safe rigging, and lifting of the control panels
during installation.
2.!Each panel shall be provided with full height, fully gasketed access doors where
shown. Doors shall be provided with a three-point stainless steel latch and heavy-duty
stainless-steel locking handle. Rear access doors (if included) shall be conveniently
arranged and sized such that they extend no further than 24 inches beyond the panel
when opened to the 90-degree position. Front and side access doors shall be as
shown. Panel access doors shall be provided with full length, continuous, piano type
stainless steel hinges with stainless steel pins. Front access doors with mounted
instruments or control devices shall be of sufficient width to permit door opening
without interference from flush mounted instruments.
3.!The panels, including component parts, shall be free from sharp edges and welding
flaws. Wiring shall be free from kinks and sharp bends and shall be routed for easy
access to other components for maintenance and inspection purposes.
4.!The panel shall be suitable for top and bottom conduit entry as required by the
Electrical Drawings. For top mounted conduit entry, the panel top shall be provided
with nominal one-foot square removable access plates, which may be drilled to
accommodate conduit and cable penetrations. All conduit and cable penetrations shall
be provided with ground bushings, hubs, gasketed locknuts, and other accessories as
required to maintain the NEMA rating of the panel and electrical rating of the conduit
system.
5.!All panels in indoor, environmental controlled environments (air conditioned) shall be
NEMA 12 unless otherwise noted. All panels installed indoors, in non-environmental
controlled environments or panels installed in outdoors shall be NEMA 4X unless
otherwise noted. All panels located in a hazardous location shall be rated for the type
of hazard (e.g., NEMA 7 for Class 1, Division 1).
B.!Freestanding and Floor-Mounted Vertical Panels
1.!Freestanding and floor-mounted vertical panels shall meet the NEMA classification as
shown on the drawings or specified herein. The panels shall be constructed of 12-
gauge sheet steel, suitably braced internally for structural rigidity and strength. All
NEMA 4X rated panels shall be constructed of type 304 stainless steel, unless FRP is
specifically indicated to be provided. Front panels or panels containing instruments
shall be not less than 10-gauge stretcher leveled sheet steel, reinforced to prevent
warping or distortion.
C.!Wall and Support Channel Mounted Panels
1.!All wall and support channel mounted panels shall meet the NEMA classification as
shown on the drawings or specified herein. The panels shall be constructed of not less
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0537-038-01 COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
than USS 14-gauge steel, suitably braced internally for structural rigidity and strength.
All NEMA 4X rated wall mounted panels shall be constructed of type 304 stainless
steel with white polyester powered coated paint, factory applied from the
manufacturer, unless FRP is specifically indicated.
D.!Finish Requirements
1.!All sections shall be descaled, degreased, filled, ground and finished. The enclosure
when fabricated of steel shall be finished with 2 rust resistant phosphate prime coats
and 2 coats of enamel, polyurethane, or lacquer finish which shall be applied by either
the hot air spray or conventional cold spray methods. Brushed anodized aluminum
panels will not require a paint finish.
2.!The panels shall have edges ground smooth and shall be sandblasted and then
cleaned with a solvent. Surface voids shall be filled and ground smooth.
3.!Immediately after cleaning, 1 coat of a rust-inhibiting primer shall be applied inside
and outside, followed by an exterior intermediate and topcoat of a 2-component type
epoxy enamel. A final sanding shall be applied to the intermediate exterior coat
before top coating.
4.!Apply a minimum of 2 -colored lacquer, on
the panel interior after priming.
5.!Unless otherwise noted, the finish exterior colors shall be ANSI 61 gray with a
textured finish.
6.!NEMA 4X Stainless Steel panels installed outdoors shall have an additional
requirement of white polyester powered coated paint, factory applied from the
manufacturer.
E.!Print storage pockets shall be provided on the inside of each panel. The storage pockets
shall be steel, welded on to the door, and finished to match the interior panel color. The
storage pocket shall be sufficient to hold all of the prints required to service the equipment,
and to accommodate 8.5x11 inch documents without folding.
F.!Folding shelf shall be provided on the inside of the door on all free-standing and floor-
mounted panels. The shelf shall be suitable for a laptop computer and shall be placed such
that an open laptop computer does not interfere with any door-mounted devices. The folded
shelf shall not interfere with any internal panel components when the door is closed. The
folding shelf shall automatically lock in the horizontal position when raised. The folding shelf
shall be approximately 18 inches wide by 12 inches deep and shall have a minimum
distributed load rating of 100 lbs. All parts shall be made of heavy gauge steel and shall be
painted white or finished to match the interior panel color.
2.5!ENVIRONMENTAL CONDITIONING
A.!Condensation Control
1.!A self-contained enclosure condensation heater with thermostat and fan shall be
mounted inside the control panel, if panel is mounted outdoors or in a non-air-
conditioned space.
a.!Enclosure heaters shall be energized from 120 V, single-phase power supply
and sized to prevent condensation within the enclosure.
b.!Locate enclosure heaters to avoid overheating electronic hardware or producing
large temperature fluctuations on the hardware.
c.!Enclosure heaters shall have an internal fan for heat distribution and shall be
controlled with adjustable thermostats. The thermostat shall have an
adjustment range of 40-90°F. Provide a circuit breaker or fused disconnect
switch within the enclosure.
d.!Enclosure heaters shall be Hoffman type DAH or equal.
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2.!Strip heaters may be provided if they are 240 V rated, powered at 120 Vac and do not
have a surface temperature higher than 60°C. Strip heaters and thermostats shall be
as manufactured by Chromalox or equal.
a.!Strip heaters shall be Chromalox, Type OT, 1.5 inches wide, 240 V, single
phase, 150 W, energized at 120 V, with rust resisting iron sheath, Catalog
No. OT-715, Product Code No. 129314, or equal. Provide sufficient wattage in
heaters to prevent condensation should the interior temperature of the
enclosure drop below the dew point.
b.!A control thermostat mounted inside the control Panel shall be Chromalox,
Type WR, single stage, Catalog No. WR-80, Product Code No. 263177, or
equal.
c.!The strip heater terminals shall be guarded by a protective terminal cover.
d.!High temperature connecting lead wire shall be used between the thermostat
and the heater terminals. Wire shall be No. 12 AWG stranded, nickel-plated
copper with Teflon glass insulation and shall be the product of Chromalox,
Catalog No. 6-CFI-12, Product Code No. 263783, or equal.
3.!Each panel shall have a 1/2-inch stainless steel condensate drain installed on a
stainless-steel conduit hub, HGTZ Series, T&B or equal, in the bottom of the
enclosure. Drain shall be O-Z Gedney DBB-50SS, or equal.
B.!Panel Interior Ambient Control
1.!The manufacturer shall provide ambient temperature control within the panel to
maintain internal temperatures below the maximum operating temperatures of the
panel components. An ambient temperature range of minus 20-40°C.
2.!The manufacturer shall provide panel internal heat rise calculations to show that the
panel internal temperatures will be maintained below the maximum operating
temperatures of the panel components.
3.!The calculation shall show all the internal and external heat gain loads, the expected
internal temperature rise in °C above the specified ambient, If the specified
temperature range cannot be met, an air conditioning system shall be provided with
sufficient capacity to maintain the temperature within the specified limits. Panels, for
which the calculated heat rise exceeds 40°C, shall have an air conditioning system
sized as required to reduce the heat rise to 40°C or less, without violating the NEMA
rating of the enclosure.
4.!The air conditioner shall have the following features:
a.!Use CFC-free R134a refrigerant.
b.!Have fully gasketed flanges on all four mounting edges for a watertight seal
that maintains NEMA 4X rating of the panel.
c.!Thermostatic low temperature control to provide energy efficient operation and
prevents over-cooling.
d.!EMI/RFI suppressor to minimize transient spikes during compressor on/off
cycling.
e.!Separated blower-driven evaporator and condenser air systems for closed loop
cooling.
f.!UL listed.
g.!Stainless steel enclosure.
h.!Internal corrosion resistant coating.
i.!Low ambient kit.
j.!Short cycle protector.
k.!The air conditioning unit shall be Hoffman, Thermo Electric or approved equal.
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2.6!CORROSION CONTROL
A.!Panels shall be protected from internal corrosion by the use of corrosion-inhibiting vapor
capsules as manufactured by Northern Technologies International Corporation, Model Zerust
VC; Hoffman Model AHCI; or equal.
2.7!INTERNAL POWER CIRCUIT DEVICES
A.!Main Circuit Protective Device
1.!Unless otherwise shown on the Drawings, the main circuit protective device shall be a
molded case (MCCB), 3-Pole, 600 V, fixed type, manually operated with stored energy
closing mechanism. Trip device shall be solid state with adjustable long time pickup
and delay; adjustable short time pickup and delay; short time inverse time switch;
2.!Provide a flange mounted main power disconnect operating handle with mechanical
interlock having a bypass that will allow the panel door to open only when the switch
is in the "OFF" position. Where panels are shown or specified with inner and outer
doors, disconnecting handles and controls shall be located on the inner door.
B.!Motor Starter
1.!Type:
a.!Magnetic Controller: NEMA ICS 2, Class A, full voltage, non-reversing, across
the line, unless otherwise indicated.
b.!Overload Relay: Ambient-compensated type with inverse-time-current
characteristic and NEMA ICS 2, Class 20 tripping characteristic. Provide with
heaters or sensors in each phase matched to nameplate full-load current of
specific motor to which they connect and with appropriate adjustment for duty
cycle.
2.!Contactors:
a.!Size contactors according to Drawings. Sizes below NEMA 1 are not acceptable.
Provide three main poles, the number and type of auxiliary contacts to perform
the required functions and two spare auxiliary contacts, one normally open and
one normally closed, rated 10 Amps (NEMA contact rating designation A600).
b.!Use double break contacts of silver-cadmium oxide or similar material to
minimize sticking or welding.
c.!Provide contactor coils suitable for continuous operation at 120 V, 60 Hz.
3.!Unless otherwise indicated larger on the Drawings, use the following minimum starter
sized for motor horsepower and voltage. Under no circumstances shall smaller sizes
be used even if mistakenly shown on the Drawings; IEC starters and dual rated
IEC/NEMA starters shall not be acceptable.
Table 1
NEMA Size Starter Horsepower 480 V Horsepower 208 V
1 Up to 7.5 Up to 5
2 20 7.5
3 40 20
4 75 36
5 100 --
C.!Variable Frequency Drives
1.!Description: NEMA ICS 2, pulse-width-modulated, variable frequency controller; listed
and labeled as a complete unit and arranged to provide variable speed of an
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NEMA MG 1, Design B, 3-phase, induction motor by adjusting output voltage and
frequency.
a.!Provide unit suitable for operation of premium-efficiency motor as defined by
NEMA MG 1.
2.!Design and Rating: Match load type such as fans, blowers, and pumps; and type of
connection used between motor and load such as direct or through a power-
transmission connection.
3.!Output Rating: 3-phase; 6-60 Hz, with voltage proportional to frequency throughout
voltage range.
4.!Unit Operating Requirements:
a.!Input ac voltage tolerance of 380-500 V, plus or minus 10%.
b.!Input frequency tolerance of 60 Hz, plus or minus 6%.
c.!Minimum Efficiency: 96% at 60 Hz, full load.
d.!Minimum Displacement Primary-Side Power Factor: 96%.
e.!Overload Capability: 1.1 times the base load current for 60 sec.; 2.0 times the
base load current for 3 sec.
f.!Starting Torque: 100% of rated torque or as indicated.
g.!Speed Regulation: Plus or minus 1%.
h.!Ambient Temperature: 0-40°C.
5.!Isolated control interface allows controller to follow control signal over an 11:1 speed
range.
a.!Electrical Signal: 4-20 mA at 24 V.
6.!Internal Adjustability Capabilities:
a.!Minimum Speed: 5-25% of maximum rpm.
b.!Maximum Speed: 80-100% of maximum rpm.
c.!Acceleration: 2 to a minimum of 22 sec.
d.!Deceleration: 2 to a minimum of 22 sec.
e.!Current Limit: 50 to a minimum of 110% of maximum rating.
7.!Self-Protection and Reliability Features:
a.!Input transient protection by means of surge suppressors.
b.!Undervoltage and overvoltage trips; inverter over-temperature, overload, and
overcurrent trips.
c.!Motor Overload Relay: Adjustable and capable of NEMA 250, Class 20
performance.
d.!Notch filter to prevent operation of the controller-motor-load combination at a
natural frequency of the combination.
e.!Instantaneous line-to-line and line-to-ground overcurrent trips.
f.!Loss-of-phase protection.
g.!Reverse-phase protection.
h.!Short-circuit protection.
i.!Motor over-temperature fault.
8.!Automatic Reset/Restart: Attempts three restarts after controller fault or on return of
power after an interruption and before shutting down for manual reset or fault
correction. Restarting during deceleration shall not damage controller, motor, or load.
9.!Power-Interruption Protection: Prevents motor from re-energizing after a power
interruption until motor has stopped.
10.!Panel-Mounted Operator Station: Start-stop and auto-manual selector switches with
manual speed control potentiometer and elapsed time meter.
11.!Integral Disconnecting Means: NEMA AB 1, molded-case switch with lockable handle.
12.!Remote Indicating Circuit Terminals: Mode selection, controller status, and controller
fault.
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13.!Line Reactor: Unit shall have 5% Line Reactor and 5% dc Bus Choke, unless specified
otherwise.
14.!Manufacturers: Subject to compliance with requirements, available manufacturers
offering products that may be incorporated into the Work include, but are not limited
to, the following:
a.!Allen Bradley.
b.!Danfoss.
c.!Square D
d.!General Electric
e.!Eaton.
f.!WEG
D.!Power Terminal Blocks
1.!Power Wire Terminal Blocks (Motors, Solenoids, Valves, etc.):
a.!Terminal blocks shall be NEMA Open System. Blocks shall be one-piece molded
plastic blocks with screw type terminals and barriers rated for 600 V.
b.!Terminals shall be double sided and supplied with removable covers to prevent
accidental contact with live circuits.
c.!Terminals shall have permanent, legible identification, clearly visible with the
protective cover removed.
d.!Wires shall be terminated to the terminal blocks with crimp type, pre-insulated,
ring-tongue lugs. Lugs shall be of the appropriate size for the terminal block
screws and for the number and size of the wires terminated.
2.!Terminal Tags, Covers and Markers:
a.!Each terminal strip shall have a unique identifying alphanumeric code
designation at one end and a plastic marking strip running the entire length
with a unique number for each terminal.
b.!Assign terminal strip numbers from the number "1" and continuing in ascending
cardinal order. The terminal strip designation shall be the letters "TB" followed
by the terminal strip number. The strip and terminal point designations shall be
machine printed and 1/8-inch high.
E.!Phase Failure/Undervoltage Pump Protection
1.!Where required in equipment specification, an independent power monitor shall be
provided on the load side of the pump disconnects to monitor incoming voltage and
provide protection to the motors. These power monitors shall detect incoming service
abnormalities including phase-loss, unbalance, reversal, overvoltage, undervoltage
and rapid cycling protection and provide automatic cutout of pumps and provide local
alarm. Upon detection that incoming power has returned to normal, the unit will
restore pump operation and discontinue alarm. This device shall have a nominal 2-
4 sec. dropout delay and (2-300 sec.) adjustable restoration time delay.
2.!The unit shall protect itself from voltage spikes and transients with internal transient
protection meeting IEEE 587 standards.
3.!The power monitor system shall also include a stagger time delay function providing
time delay between lead and lag pump start to eliminate simultaneous starting of
motors upon return of system power. This feature shall be operation in all modes of
pump operation. The monitors will be SYMCON 460 VBM.
2.8!PANEL MOUNTED CONTROL OR INDICATING DEVICES
1.!Combined Sounder and LED Beacon
a.!Where indicated panels shall be provided with a "Combined Sounder and LED
Beacon". The combined sounder and flashing LED beacon shall have
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polycarbonate housing and lens, 45mm size, 22mm mounting hole, and
Type4X. Control logic shall be provided so that the unit can be silenced, until
alarm is cleared and reset. The sounder shall have average dBAat1m of 103
and shall be configured as pulsing. The combined sounder and flashing LED
beacon shall be as manufactured by Eaton, Model RoLP Maxi Solista; or equal.
2.Push Buttons, Selector Switches and Pilot Lights
a.Push buttons, Type4/4X/13corrosion-resistant/watertight/oiltightplastic,
selector switches and pilot lights shall be 30.5mmtype.
b.Push buttons, selector switches and pilot lights shall have electrical ratings of:
Dielectric strength: 2200V for 1min.
Electrical design life cycles: 10,000,000 at maximum rated load
c.Push buttons, selector switches and pilot lights shall have an operating range of
minus40-131°F (minus40-55°C).
d.Illuminated devices shall offer universal LED that accepts 12-130Vac/Vdc
voltage input. Lens color shall be as follows;
a)Running, on, open: Red.
b)Stopped, off, closed:Green.
c)Alarm:Amber.
d)White:Power on
e)Blue:All other status indications not covered by the above
f)Lens caps shall be approximately 0.46inch diameter. Provide
legendfaceplates engraved to indicate the required function of each
device; rated NEMA 4X.
e.Push buttons shall have a diaphragm seal for protection from liquids, particles
and corrosive agents. Button colors shall be as follows;
a)Start, open: Red.
b)Stop, close: Green.
c)Black: All other status indications not covered by the above
f.Selector switches shall incorporate a positive detent to prevent the switch from
hanging up between positions.
Selector switches shall incorporate a positive detent to prevent the switch
from hanging up between positions.
3.Elapsed Time Meters
a.Meter shall be heavy duty, electro-mechanical, non-resettable, six digit
99999.9h Unit shall be NEMA4X rated.
b.Mounting of unit with gasket shall maintain rating of enclosure.
4.Digital Panel Meter
a.Meter shall be electronic, 3.5digit, 0.56-inch high efficiency LED display and
shall provide indicated in engineering units of measured variable. Case type
shall be watertight and dust tight (NEMA4X).
2.9INTERNAL CONTROL CIRCUIT DEVICES
A.Panel lighting
1.Panels shall be provided with a door switch activated 24VdcLED light.
B.Panel Service Receptacle
1.Panels, where indicated in equipment specifications. shall be provided with a DIN Rail
Mounted straight blade, 125V, 15Amp, non-feed-through type receptacle. Comply
with NEMAWD1, NEMAWD6, UL498, and UL943, ClassA, and include LED status
indicator light.
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C.!Panel Incoming Surge Protection
1.!Provide modular, pluggable surge protective device of the incoming power feed to the
control panel. Units shall be metal oxide varistors (MOVs) and gas-filled surge
arresters, with a maximum continuous operating voltage of 150 V.
D.!Circuit Breakers
1.!Breakers shall be thermal-magnetic, current-limiting type, UL Listed, 10 kA.
2.!Housing shall satisfy Insulation Group II/RAL 7035, shall have IP20 finger-safe design,
shall be suitable for DIN rail mounting and shall include status indicator window and
scratch-resistant and solvent-resistant printing
E.!24VDC Power Supplies
1.!Provide a 24 Vdc power supply in the control panel to power field instruments, panel
devices, etc., as required. Equip the power supply with a power on-off circuit breaker.
Size the 24 Vdc power supply to accommodate the design load plus a minimum 50%
spare capacity. Power supply shall be primary switched, DIN Rail mounted, with LED
indication and status contacts. Provide output overvoltage and overcurrent protective
devices with the power supply to protect instruments from damage due to power
supply failure and to protect the power supply from damage due to external failure.
Mount the 24 Vdc power supply such that dissipated heat does not adversely affect
other panel components.
F.!120VAC Uninterruptible Power Supply (UPS)
1.!Provide a 120 Vac UPS in the control panel to power control components, including
PLC, relays, 24 Vdc power supplies, etc. as required. Equip the power supply with a
power on/off circuit breaker. Size the UPS to accommodate the design load plus a
minimum 50% spare capacity, with 10 min. battery life at full load. UPS shall be DIN
Rail mounted, with LED indication and status contacts. Mount the UPS power supply
such that dissipated heat does not adversely affect other panel components. Provide
a maintenance bypass switch to allow the UPS to be taken out of service for
maintenance or replacement.
G.!Fuse Blocks
1.!Fuse Blocks shall be DIN Rail mounted, single level, standard size, set screw terminal,
with blown fuse indicator.
H.!Terminal Blocks 120Vac or 24Vdc
1.!Terminal blocks shall be DIN-Rail mounted, IEC screw-type, feed-through, single
level, rated IP20. Metal components shall be made of corrosion resistant materials.
The metal body shall contain a serrated pressure plate that will provide a gas-tight
connection with the conductor. Terminal Blocks shall have captive screws. Control
terminal blocks shall have a snap-in card marking system. Marking shall be computer
generated.
I.!Relays
1.!Relays Time Delay
a.!Relays shall mount on tube-type bases with pin-style socket mounting. Shall
have 10 Amp, B300, DPDT contact ratings and coil voltages as shown on
drawings and adjustable timing ranges.
2.!Relays General Purpose
a.!Relays shall have tube-base/Octal 8-pin or 11-pin terminals and "ON-OFF" flag
indicators. Contacts shall be silver nickel and have 10 Amp, B300, DPDT or
3PDT ratings. Shall have an electrical schematic on the faceplate, a clear cover
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for visual inspection and snap-in marker ability. Relays shall have LED status
indicators, push-to-test and manual override.
3.!Relays Miniature
a.!Relays shall be square-base, 4-pole, plug-in type with blade-style terminals and
"ON-OFF" flag indicators. Contacts shall be silver nickel and have 7 Amp or
10 Amp, DPDT or 4PDT ratings. Shall have an electrical schematic on the
faceplate and a clear cover for visual inspection and LED status indicators and
push-to-test button with incorporated manual override lever.
4.!Relays - PLC Interposing
a.!Relays shall be DIN Rail Mount, screw terminal, slim factor design. Shall be
pluggable, with ejector feature. Contacts shall be silver nickel and have 5 Amp,
24 Vdc or 3 Amp, 120 Vac, SPDT electro-mechanical and shall have LED status
indicators.
5.!Relays - Alternating
a.!Alternator shall be provided to sequence motors where required for lead-lag
operation. Alternator shall be Catalog No. 008-120-13SP or 009-120-23AP by
Stacon; Square D, Class 9039, Type HG-21 or equal.
6.!Timers Solid-State
a.!Timers shall be DIN rail mounted. Contacts shall be available as SPDT or DPDT,
8 Amp. Timers shall be available with On-Delay, Off-Delay, On-Delay and Off-
Delay, One-Shot, and Flasher operating modes as required on the drawings.
Timers shall have coil surge protection and adjustable timing ranges of
0.05 sec. to 60 hours as shown on drawings.
7.!Timers Programmable
a.!Timers shall be digital timing relays with LCD display and shall be socket or
panel mounted. Contacts shall be SPDT, rated 5 Amp, B300. Timers shall be
configurable for Signal On-Delay, Power On-Delay, Off-Delay, Repeat Cycle,
One-Shot, and Cumulative operating modes as required on the drawings.
Timers shall have timing ranges of 0.000 sec. to 9999 hours, depending on
selected mode and as shown on drawings.
J.!Analog Signal Surge Protection
1.!Analog signal surge protection shall be slim-factor hybrid design that combines solid-
state electronic and gas filled discharge tube to provide protection to 20 kA.
K.!Signal Isolators
1.!Signal Isolators shall be DIN Rail mounted, solid state, ASIC technology; electronic
type, with 0.15 accuracy. There shall be complete isolation between input circuitry,
output circuitry, and the power supply. Zero and span adjustment shall be provided.
Units shall be as manufactured by Action Instruments, Model Slim Pak; or approved
equal.
L.!Fiber Optic Patch Panel
1.!Provide DIN rail mounted patch panels, as indicated in equipment specifications, to
terminate cabling from the network elements. Physical locations and number of Type
SC connectors supported shall be sufficient to terminate all fibers at each fiber drop
point.
M.!CAT 6 Patch Panel
1.!Provide DIN rail mounted patch panels, as indicated in equipment specifications, to
terminate cabling from the network elements. Performance parameters, including
NEXT, Attenuation and Return Loss shall meet Category 6E Cabling Standard.
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2.10INTERNAL WIRING REQUIREMENTS
1.120Vac and 24Vdc Wiring
a.All interconnecting wiring shall be stranded, type MTW, and shall have 600V
insulation and be rated for not less than 90°C. Wiring for systems operating at
voltages in excess of 120Vac shall be segregated from other panel wiring
either in a separate section of a multi-section panel or behind a removable
Plexiglas or similar dielectric barrier. Panel layout shall be developed such that
technicians shall have complete access to 120Vac and lower voltage wiring
systems without direct exposure to higher voltages.
b.Power distribution wiring on the line side of fuses or breakers shall be 12AWG
minimum. Control wiring on the secondary side of fuses shall be 14AWG
minimum. Electronic analog circuits shall utilize 18AWG shielded, twisted pair,
cable insulated for not less than 600V.
c.Power and low voltage dc wiring systems shall be routed in separate wireways.
Crossing of different system wires shall be at right angles. Different system
wires routed parallel to each other shall be separated by at least 6-inches.
Different wiring systems shall terminate on separate terminal blocks. Wiring
troughs shall not be filled to more than 60% visible fill.
d.Terminations
All wiring shall terminate onto single tier terminal blocks, where each
terminal is uniquely and sequentially numbered. Direct wiring between
field equipment and panel components is not acceptable. Wiring for
input/output (I/O) points for the PLC shall be allowed to terminate directly
to interposing relay or surge protector.
Multi-level terminal blocks or strips are not acceptable.
Terminal blocks shall be arranged in vertical rows and separated into
groups (power, ac control, dc signal). Each group of terminal blocks shall
have a minimum of 25% spares.
Discrete inputs and outputs (DI and DO) shall have two terminals per point
with adjacent terminal assignments. All active and spare PLC and
controller points shall be wired to terminal blocks. Wiring for I/O points for
the PLC shall be allowed to terminatedirectly to interposing relay.
Analog inputs and outputs (AI and AO) shall have three terminals per
shielded pair connection with adjacent terminal assignments for each
point. The third terminal is for shielded ground connection for cable pairs.
Ground the shielded signal cable at the PLC cabinet. All active and spare
PLC and controller points shall be wired to terminal blocks. Wiring for I/O
points for the PLC shall be allowed to terminate directly to surge protector.
Wire and tube markers shall be the sleeve type with heat impressed letters
and numbers.
Only one side of a terminal block row shall be used for internal wiring. The
field wiring side of the terminal shall not be within 6inches of the side
panel or adjacent terminal or within 8inches of the bottom of free-
standing panels, or within 3inches of stanchion mounted panels, or
3inches of adjacent wireway.
Circuit power from the SCADA cabinet out to field devices (switches, dry
contacts etc.) that are used as discrete inputs to the PLC input cardsshall
be isolated with an isolating switch terminal block with flip cover that is
supplied with a dummy fuse. Isolation switch block shall be an Allen
Bradley Model1492-H7 or equal. One isolating switch terminal block per
loop numbered piece of equipmentand one per spare I/O point is
acceptable.
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0537-038-01COMMON CONTROL PANEL REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
Wire Tagging:
a)Panel connection wiring shall be tagged at terminations with
machine printed slip on type tags.
b)Provide wire-cable tag designations on all wiring diagrams
submitted to the OWNER. Place tag within 2inches of any wiring
termination, affixing tag to prevent the tag from sliding more than
2inches from the terminal as the result of gravity and vibration.
e.All wiring to hand switches and other devices, which are live circuits
independent of the panel's normal circuit breaker protection, shall be clearly
identified as such.
f.All wiring shall be clearly tagged and color coded. All tag numbers and color
coding shall correspond to the panel wiring diagrams and loop drawings. All
power wiring, control wiring, grounding, and dc wiring shall utilize different
color insulation for each wiring system used. The color coding scheme shall be:
a)Incoming 120Vac Hot:Black
b)120Vac Hot wiring downstream of panel circuit breaker:Red
c)120Vac Hot wiring derived from a UPS system:Red with Black
stripe
d)120Vac neutral:White
e)Ground:Green
f)Dc power or control wiring:Blue
g)Dc analog signal wiring:Black (+), White (-)
h)Foreign voltage:Yellow
g.Each field instrument furnished as deriving input power from the control
panel(s) shall have a separate power distribution circuit with a circuit breaker
or fuse and blown fuse indication. All instruments requiring 120Vac power shall
be powered from the UPS source in the panel where the instrument signals
lands.
h.Wiring trough for supporting internal wiring shall be plastic type with snap-on
covers. The side walls shall be open top type to permit wire changing without
disconnecting. Trough shall be supported to the subpanel by stainless steel
screws. Trough shall not be bonded to the panel with glue or adhesives.
i.Each panel shall be provided with an isolated copper grounding bus for all
signal and shield ground connections. Shield grounding shall be in accordance
with the instrumentation manufacturer's recommendations.
j.Each panel shall be provided with a separate copper power grounding bus
(safety) in accordance with the requirements of the National Electrical Code.
k.Field Entrance Internal Wiring:
Field entrance internal wiring shall be neatly grouped by circuit and bound
by plastic tie wraps. Circuit groups shall be supported so that circuit
terminations are not stressed. In addition, low signal wiring (mV and mA)
shall be bundle separately from the rest of the control wiring.
All field wiring shall be tagged and coded with an identification number.
Coding shall be typed on a heat shrinkable tube applied to each end of the
wire. The marking shall be a permanent, non-smearing, solvent-resistant
type similar to Raychem TMS-SCE.
All conduit entering or leaving equipment shall be coordinated, in advance
with the panel installer, so that the conduit entrances to the enclosure are
directly below the termination area for immediate termination. Conduits
shall not enter the top or side of the panel unless approved in writing by
the OWNER and ENGINEER.
l.Fusing of PLC Inputs and Outputs:
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All PLC analog inputs and outputs shall be individually fused for each
channel.
All discrete inputs and outputs shall be buffered with relays from the field
connections. Discrete pointsshall be fused for each circuit group with no
less than one fuse per PLC I/O card.
m.Buffering PLC Discrete Inputs and Outputs:
All PLC discrete inputs and outputs shall be individually buffered with
relays as specified. Where field voltage is ac reed type relays shall not be
used.
n.Analog Input and Output Wiring:
Provide a fuse for each analog signal. Each analog I/O and each spare
analog I/O shall be furnished with a surge protection device hardwired to
the fed-through terminal block.
2.11PROGRAMMABLE LOGIC CONTROLLER (CHASSIS MOUNTED)
A.General
1.Provide Programmable Logic Controller equipment with the required memory and
functional capacity to perform the specified sequence of operation with the scheduled
input and output points.
2.Processor Systems shall include processor, power supply, I/O modules,
communication modules, redundancy modules, and remote interface modules as
required to meet system requirements.
3.All equipment furnished shall be designed and constructed so that in theevent of
power interruption the systems shall go through an orderly shutdown with no loss of
memory and resume normal operation without manually resetting when power is
restored.
4.The PLC shall be capable of stand-alone operation in the event of failure ofthe
communication link to the Plant Control System.
5.Backup Remote Input/Output Units shall include input/output modules, interface
modules, communication modules, and power supply to meet system input and
output requirements.
6.Agency and environmental specifications:
a.Electrical supply voltage to the PLC shall be 120Vac, plus or minus15%, 48-
63Hz. PLC system power supplies shall be fused for overload protection.
b.All products shall have corrosion protection.
7.All necessary cables shall be included. All cables and connectors shall be as specified
by the manufacturer. Cables shall be assembled and installed per the manufacturer
recommendations.
B.Subject to compliance with the Contract Documents, the following manufacturers are
acceptable:
1.Allen-Bradley, Compact Logix
2.General Electric, RX3i
3.Modicon, M340
C.Programming Languages
1.Each PLC shall support IEC Standard61131-3 for all of the following programming
languages:
2.Ladder (LD)
3.Function Block Diagram (FBD)
4.Structured Text (ST)
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5.PLC shall support user defined functions for customization and user defined tag
structures.
6.PLC shall have application-specific instructions for process, drive, batch, motion, and
safety applications built into the controller.
D.Central Processor Unit (CPU)
1.Each processor shall have the maximum IEC Program Memory size available at time
of procurement.
2.Provide hardware employing identical revisions of software and firmware as
applicable.
3.Processor shall have a minimum IEC program memory size of 1024kB.
4.The CPU shall contain a minimum of 1serial configuration port and 2Ethernet ports.
5.The CPU shall be able to do time synchronization for the system.
E.Physical Construction (Chassis)
1.The PLC shall be of the modular construction, consisting of a back plane, plug in
modules for the processor, communication modules, I/O modules and expansion
modules.
F.Power Supply (PS)
1.The power supply shall be 120V, 60Hz, and shall be sized for the total quantity of
modules including the power requirement of spare I/O module slots.
G.I/O Modules: The following types of process I/O interface capabilities shall be provided for
the PLC:
1.Discrete Input Requirements:
a.Responsible for the PLC interface with the status and alarm contacts.
For the "dry" contacts: PLC shall sense the states of these contacts by
applying a voltage and observing the extent to which current flows.
This voltage shall be obtained from a separate, isolated power supply
furnished by the CONTRACTOR
Voltage applied across the open contacts shall be 24Vdc (nominal), or
110Vac.
b.Exact input configuration sized to meet the existing discrete input needs as
specified on the Drawings.
c.Final configuration based on the standard product offering of the PLC
manufacturer.
d.Discrete inputs shall be 24Vdc and be individually buffered with external
relays.
e.Number of Points per Card: 16
2.Discrete Output Requirements:
a.Discrete output logic shall process the control commands received from the
common logic. Control schemes, in which a single message with undetected
errors can cause a false command, shall beunacceptable.
b.Discrete output drive circuitry shall be designed such that any single logic
component failure in the PLC does not energize a discrete output.
c.Exact output configuration sized to meet existing discrete output needs as
specified on the Drawings.
d.Final configuration based on the standard product offering of the PLC
manufacturer.
e.Discrete outputs shall be of the relay type and individually buffered with
external relays.
f.Number of Points per Card: 16
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3.!Analog Output Requirements:
a.!Provide analog output modules having a 4-20 mA at 24 Vdc; suitable for
interfacing to an electronic three mode controller or direct to a variable
frequency drive.
b.!Analog outputs are driven from the isolated 24 Vdc power supply supplied in
the PLC Panel. The module shall have broken wire fault detection.
c.!Exact output configuration sized to meet analog output needs as specified on
the Drawings.
d.!Final configuration based on the standard product offering of the PLC
manufacturer.
e.!Number of Points per Card: 8
4.!Analog Input Requirements:
a.!Analog inputs from the transducers shall be 4-20 mA dc and all transducer
power shall be provided by the dedicated 24 Vdc plus 10% power supply
supplied in the PLC Panel, or from an isolated output of the field device. The
module shall be Bi-Polar with broken wire and Out of Range fault detection.
b.!Exact input configuration sized to meet the analog input needs as specified on
the Drawings.
c.!Final configuration based on the standard product offering of the PLC
manufacturer.
d.!Number of Points per Card: 8
H.!PLC Power Supply: PLC power supplies shall be supplied with 110 Vac. PLC power supplies
2.12!OPERATOR INTERFACE TERMINALS (OIT)
A.!OITs shall be mounted on control panels, where shown on drawings.
B.!Manufacturers
1.!Provide operator interface terminals (OIT) from one of the following:
a.!Allen-Bradley PanelView Plus 6 series
b.!GE Loaded QuickPanel View series
c.!Pro-face AGP3000/ AST3000 series
d.!Siemens SIMATIC HMI IPC series
C.!Software
1.!The Operator Interface Terminal shall be pre-packaged with all configuration and
programming software necessary to perform functions as shown on drawings and
within the specifications.
2.!The integrated OIT software shall have the following features
a.!Trending
b.!Data Logging
c.!Alarms
d.!Graphic Symbols
e.!Animations
D.!I/O Ports and Devices
1.!The OIT shall have a minimum of one Ethernet 10/100 Mbps for connectivity or
programming.
2.!The OIT shall have a minimum of one Serial RS 232 port.
3.!Compact flash ports shall be Type 2.
4.!The OIT shall have a minimum of one USB port.
E.!Display
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1.!The OIT display size shall be a minimum of 6 inches for wall mounted panels and
12 inches for floor mounted panels
2.!The type of display for the OIT shall be Color Active Matrix TFT.
3.!Display shall support touch screen input.
F.!Environmental
1.!Rating: OIT shall be rated to maintain the rating of the control panel it will be
mounted in.
2.!Temperature: Operating temperature range of the OIT shall range 0-50°C.
G.!Operator screen shall be provided with a hinged screen to protect screen of sun light. Sun
shield shall be Shade Aide by Smith and Loveless, Inc.
2.13!PROGRAMMING CABLES
A.!Provide two programming cables for each type of PLC to be programmed.
2.14!MEMORY MAPS REQUIREMENTS
A.!The control panel vendors shall comply with the following;
1.!Submit memory map of PLC registers to be transmitted to SCADA as part of their
submittal.
2.!All vendors supplying control panels that communicate with the plant SCADA network
shall submit a memory map of PLC registers to the Control System Integrator no later
than 30 days prior to the scheduled shipment of the vendor equipment to the site.
Vendor shall contact and coordinate with the Control System Integrator to ensure
compatible configuration of the vendor PLCs in order to match the facility network.
Vendor shall configure the network addresses in their equipment to match the
addresses determined by the Control System Integrator. Software communication
shall be provided in contiguous registers. One set of registers shall be provided for
writing discrete-type information, and one set shall be provided for reading discrete-
type information. One set of registers shall be provided for writing floating-point
information, and one set shall be provided for reading floating-point information.
2.15!INDUSTRIAL ETHERNET PROTOCOL CONVERTER
A.!Subject to compliance with the Contract Documents, the following manufacturers are
acceptable:
1.!Digi
a.!Model: Digi One IA Industrial Serial Server
2.!B&B Electronics
a.!Model: MESR900 Series Industrial Modbus Ethernet to Serial Gateways
B.!Environmental
1.!Operating temperature: 32-140°F
2.!Operating humidity: 1090% Non-condensing
3.!Storage Temperature: 32-140°F
C.!Physical
1.!Power Supply: 24 Vdc
2.!Microprocessor based managed type.
3.!DIN Rail mountable.
4.!Class 1 Division 2 rated
D.!Functional Performance
PLUMMER ASSOCIATES, INC. 40 05 91 - PAGE 20 OF 23 BID SET
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1.!Per Port status LED indication.
2.!Wire Speed switching.
3.!10/100 BaseT ports with RJ-45 connectors for Category 6 cabling.
4.!ST or SC type Fiber Optic Connectors for 100BaseFX, 1000BaseSX for Multimode Fiber
and 1000BaseLX for Single Mode Fiber as shown on the drawings.
5.!RS 232 Ports with terminals. Selectable link termination (100 ~120
E.!Options and Accessories Required:
1.!Provide minimum 3-year warranty.
2.!The protocol interface shall implement the following:
a.!All data shall be available and/or mirrored within the Modbus 4x or "Holding
Register" memory area.
b.!Register 4x00001 shall exist and be readable-writable to allow simple,
predictable "communication tests".
3.!The media protocol converter shall meet the following criteria:
a.!The converter shall support 10/100Base-T Ethernet. The serial port speed
(baud rate) shall support 230 kBd. The protocol shall support Ethernet IP,
Modbus TCP and Modbus RTU/ASCII. Protocol shall be Web Browser
configurable.
2.16!INDUSTRIAL ETHERNET MEDIA CONVERTER
A.!Subject to compliance with the Contract Documents, the following manufacturers are
acceptable:
1.!Beldon
2.!B & B Electronics
3.!Moxa
4.!N-TRON
5.!SIXNET
B.!Environmental
1.!Operating temperature: 32-104°F
2.!Operating humidity: 2095% Non-condensing
3.!Storage Temperature: minus 40-158°F
C.!Physical
1.!Power Supply: 24 Vdc
2.!Microprocessor based managed type.
3.!DIN Rail mountable.
D.!Functional Performance
1.!Per Port status LED indication.
2.!Wire Speed switching.
3.!10/100BaseT ports with RJ-45 connectors for Category 6 cabling.
4.!ST or SC type Fiber Optic Connectors for 100BaseFX, 1000BaseSX for Multimode Fiber
and 1000BaseLX for Single Mode Fiber as shown on the drawings.
2.17!MISCELLANEOUS
A.!Face-mounted equipment shall be flush or semi-flush, with flat black escutcheons. Cutouts
for future equipment and holes resulted from removal of existing devices shall be blanked
off with suitable covers as required to retain the cabinet's NEMA rating. Component
identification shall be hot ink stamped on the panel interior.
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B.!Hardware and Fittings: All miscellaneous hardware and fittings shall be Type 316 stainless
steel.
C.!The bottom 12 inches of free-standing panels shall be free of all devices, including terminal
strips, to provide ease of installation and testing. If top fed, the top 12 inches of free-
standing panels shall be free of all devices.
2.18!FACTORY TESTING - GENERAL
A.!The entire control panel shall be completely assembled, wired, and adjusted at the factory
operational test to insure the workability and reliable operation of the equipment.
B.!The operational test shall include the proper connection of supply and control voltage and,
as far as practical, a mockup of simulated control signals and control devices shall be fed
into the boards to check for proper operation.
C.!Factory test equipment and test methods shall conform to the latest applicable requirements
of ANSI, IEEE, UL, and NEMA standards, and shall be subject to the OWNER and
2.19!EXTRA MATERIALS
A.!Furnish extra materials that match products installed and that are packaged with protective
covering for storage and identified with labels describing contents.
B.!Spare part requirements shall be as indicted in the table below.
Percent of Each
Description No Less Than
Type and Size Used
Dc power supplies 20 2
Fuses 20 10
Relays and bases 20 10
Analog surge protectors 20 3
Power line surge protectors 20 2
PART 3 - EXECUTION
3.1!
A.!Installer shall be specialized in installing this type of equipment with minimum 5 years
documented experience. Experience documentation shall be submitted for approval prior to
beginning work on this project.
3.2!EXAMINATION
A.!Examine installation area to assure there is enough clearance to install the equipment.
B.!Housekeeping pads shall be included for the floor mounted panels as detailed on the
drawings.
C.!Check concrete pads and baseplates for uniformity and level surface.
D.!Verify that the equipment is ready to install.
E.!Verify field measurements are as instructed by manufacturer.
3.3!INSTALLATION
A.!The CONTRACTOR shall install all equipment per the manufacturer's recommendations and
contract drawings.
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B.!Conduit hubs for use on raceway system pull and junction boxes shall be watertight,
threaded aluminum, insulated throat, stainless steel grounding screw.
C.!Install required safety labels.
3.4!RACEWAY SEALING
A.!Where raceways enter control panels containing electrical or instrumentation equipment, all
entrances shall be sealed with 3M 1000NS Watertight Sealant.
B.!This requirement shall be strictly adhered to for all raceways in the conduit system.
3.5!FIELD QUALITY CONTROL
A.!Inspect installed equipment for anchoring, alignment, grounding and physical damage.
B.!Check tightness of all accessible electrical connections. Minimum acceptable values are
specified in manufacturer's instructions.
C.!Provide laminated copies of the control schematics along with the final approved I/O list in
each enclosure door pocket.
3.6!CLEANING
A.!Remove all rubbish and debris from inside and around the panel. Remove dirt, dust, or
concrete spatter from the interior and exterior of the equipment using brushes, vacuum
cleaner, or clean, lint free rags. Do not use compressed air.
3.7!EQUIPMENT PROTECTION AND RESTORATION
A.!Touch-up and restore damaged surfaces to factory finish, as approved by the manufacturer.
If the damaged surface cannot be returned to factory specification, the surface shall be
replaced.
3.8!TESTING, COMMISSIONING AND TRAINING
A.!Testing and Commissioning: Accomplished in accordance with the requirements of Section
01 70 00 Execution and Closeout Requirements."
B.!Training: Accomplished in accordance with the requirements of Section 01 70 00 "Execution
and Closeout Requirements."
END OF SECTION
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SECTION 40 05 93
COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT
PART 1 - GENERAL
1.1!SUMMARY
A.!Section includes general requirements for single-phase and polyphase, general-purpose,
horizontal, small and medium, squirrel-cage induction motors, 250 Hp and smaller, for use
on ac power systems up to 600 V and installed at equipment manufacturer's factory or
shipped separately by equipment manufacturer for field installation.
B.!Related Sections include but are not necessarily limited to:
1.!Division 00 - Procurement and Contracting Requirements.
2.!Division 01 - General Requirements.
1.2!REFERENCES
A.!Motors shall be designed, built, and tested in accordance with the latest revision of the
following standards:
1.!National Electrical Manufacturers Association Inc. (NEMA)
a.!NEMA MG1 - Motors and Generators.
b.!NEMA MG2 - Safety Standard for Construction and Guide for Selection,
Installation and Use of Electric Motors and Generators.
c.!NEMA MG3 - Sound Level Prediction for Installed Rotating Electrical Machines.
2.!National Fire Protection Association (NFPA)
a.!NFPA-70 - National Electrical Code.
3.!Underwriters Laboratories, Inc. (UL)
a.!UL-1004 - Electric Motors.
4.!Institute of Electrical and Electronics Engineers, Inc. (IEEE)
a.!IEEE Std 1 - General Principles for Temperature Limits in the Rating of Electric
Equipment.
b.!IEEE Std 43 - Recommended Practice for Testing Insulation Resistance of
Rotating Machinery.
c.!IEEE Std 85 - Test Procedures for Airborne Sound Measurements on Rotating
Electric Machinery.
d.!IEEE Std 112 Standard Test Procedure for Polyphase Induction Motors and
Generators.
e.!IEEE Std 275 - Recommended Practice for Thermal Evaluation of Insulation
Systems for AC Electric Machinery Employing Form-wound Pre-insulated Stator
Coils, Machines Rated 6,900 V and Below.
f.!IEEE Std 429 - Standard Test Procedure for the Evaluation of Sealed Insulation
Systems for AC Electric Machinery Employing Form-wound Stator Coils.
g.!IEEE Std 1349 Guide for the Application of Electric Motors in Class 1, Div 2
Hazardous Locations.
5.!Anti-Friction Bearing Manufacturer's Association Inc. (AFBMA):
a.!AFBMA-9 & 11 - Load Ratings and Fatigue Life for Roller Bearings.
1.3!ADMINISTRATIVE REQUIREMENTS
A.!Coordination
1.!Coordinate features of motors, installed units, and accessory devices to be compatible
with the following:
PLUMMER ASSOCIATES, INC. 40 05 93 - PAGE 1 OF 8 BID SET
0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
a.!Motor controllers.
b.!Torque, speed, and horsepower requirements of the load.
c.!Ratings and characteristics of supply circuit and required control sequence.
d.!Ambient and environmental conditions of installation location.
2.!Unit Responsibility: Motors shall be furnished under other sections as a part of the
driven equipment. The CONTRACTOR is responsible for all coordination between the
various components, as well as for the warranty.
1.4!SUBMITTALS
A.!Shop Drawings: Include the following:
1.!Manufacturer.
2.!Rated full load horsepower.
3.!Rated volts.
4.!Number of phases.
5.!Frequency in hertz.
6.!Locked rotor amperes (LRA) at rated voltage or NEMA code letter.
7.!NEMA design letter.
8.!Bearing Type.
9.!Service Factor.
10.!Nominal speed at full load.
11.!Full Load Amperes (FLA)
12.!Efficiency at 1/2, 3/4 and full load.
13.!Power factor at no load,1/2, 3/4 and full load.
14.!NEMA insulation system classification. For motors required to install outdoors, include
information showing compliance with the intent of paragraph 1.4.B.
B.!Integral Horsepower Motors 40HP and Larger: In addition to the information listed above,
include:
1.!No load amperes.
2.!Safe stall time.
3.!Motor manufacturer's recommended maximum power factor correction capacitor kva
that can safely be switched with the motor.
4.!Expected value of corrected power factor at no load, 1/2, 3/4 and full load.
5.!Maximum guaranteed slip at full load.
6.!Motor damaged curves for motors larger than 100HP.
C.!Include the motor data sheet at the end of this section in submittal.
1.5!QUALITY ASSURANCE
A.!Motor Compatibility. The Motor manufacturer and driven equipment manufacturer shall
guarantee that the motor included with the driven equipment is compatible with driven
equipment and complies with these Specifications. In the event that the motors described
in these Specifications cannot be applied to the application or equipment offered, the
Contractor may submit an exception, stating clearly the deviations and the reasons for such
deviations. The acceptance or rejection of such deviations shall be at the sole discretion of
the Owner/Engineer.
B.!When motors are furnished with driven equipment, the driven equipment supplier shall be
responsible for mounting the motor and driven equipment as a complete unit, correctly
aligned and coupled with the coupling or sheave specified on the driven equipment data
sheet, and for designing vibration, special, or unbalanced forces resulting from equipment
operation.
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0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
C.!Motors manufactured more than twenty four (24) months prior to the date of this Contract
will not be acceptable.
1.6!DELIVERY, STORAGE, AND HANDLING
A.!Protect equipment during shipment, handling, and storage by suitable complete enclosures.
Protect equipment from exposure to the elements and keep thoroughly dry.
B.!Protect painted surfaces against impact, abrasion, discoloration, and other damage. Repaint
damaged painted surfaces to the satisfaction of the Owner/Engineer.
C.!Equipment shall not be stored onsite without written approval of the Owner/Engineer.
Equipment must be installed in its permanent location shown on the Drawings within seven
(7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7)
calendar days, the equipment shall not be delivered to the site, but stored offsite, in an air
until such time that the site is ready for permanent installation of the equipment.
D.!Where space heaters are provided in motors, provide temporary electrical power and
operate space heaters, during jobsite storage and after motors are installed in permanent
location, until equipment is placed in service.
E.!The motor shaft shall be rotated on a monthly basis, if such is recommended or required by
the motor manufacturer, the date recorded, and copies of the record provided to the
Owner/Engineer and the manufacturer. The manufacturer shall confirm receipt of the
rotation record.
1.7!SITE CONDITIONS (NOT USED)
1.8!WARRANTY
A.!
equipment warranty.
B.!All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
PART 2 - PRODUCTS
2.1!MANUFACTURERS
A.!Manufacturers: Subject to compliance with the requirements of this Section, provide
products by one of the following:
1.!-
2.!Westinghou
3.!
4.!
5.!-
6.!-
2.2!GENERAL MOTOR REQUIREMENTS
A.!Comply with requirements in this Section except when stricter requirements are specified in
equipment schedules, Drawings or Sections.
B.!Comply with NEMA MG 1 unless otherwise indicated.
C.!Comply with IEEE P841for severe-duty motors.
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2.3!RATING
A.!Speed and Size:
1.!Speed and horsepower sizes are specified in the driven equipment specification
sections or are indicated on the Drawings.
2.!Furnish motors sufficiently sized for the particular application and with full-load rating
not less than required by the driven equipment at specified capacity.
3.!Size motors so as not to overload at any point throughout the normal operating
range.
B.!Voltage:
1.!Fractional Horsepower through 1/2 horsepower, single phase: 120 volts.
2.!Larger than 1/2 horsepower, three phase - 480 volts, unless otherwise indicated in
the drive equipment specification sections or as indicated on the Drawings.
2.4!MOTOR CHARACTERISTICS
A.!Duty: Continuous duty at ambient temperature of 40 deg C and at altitude of 3300 feet
above sea level.
B.!Capacity and Torque Characteristics: Sufficient to start, accelerate, and operate connected
loads at designated speeds, at installed altitude and environment, with indicated operating
sequence, and without exceeding nameplate ratings or considering service factor.
2.5!POLYPHASE MOTORS
A.!Description: NEMA MG 1, Design B, medium induction motor.
B.!Efficiency: Premium Efficiency, as defined in NEMA MG 1.
C.!Service Factor: 1.15.
D.!Multispeed Motors: Separate winding for each speed.
E.!Rotor: Random-wound, squirrel cage.
F.!Bearings:
1.!Motors Smaller than 1/6 Horsepower: Motor manufacturer's standard bearing is
acceptable.
2.!Motors 1/6 Horsepower and Larger: Supply these motors with grease-lubricated
antifriction ball bearings conservatively rated for 100,000 hours of continuous
operation under the total radial and thrust loads produced by the actual combination
of motor-driven equipment. Provide each motor with suitable lubrication fittings and
pressure relief devices.
3.!Oil Lubricated: If the driven equipment section specified oil-lubricated bearings for
motors, include a suitable sight gauge on each bearing with maximum and minimum
levels clearly indicated.
G.!Temperature Rise: Class B.
H.!Insulation: Class F insulation with temperature rise of a Class B system or better, meeting
the requirements of NEMA MG 1 and made of non-hygroscopic materials. The insulation
ack by moisture, acids, alkalies, and
mechanical or thermal shock for 480 volt motors. All insulated winding conductors shall be
copper.
I.!Code Letter Designation:
1.!Motors 15 HP and Larger: NEMA starting Code F or Code G.
2.!Motors Smaller than 15 HP: Manufacturer's standard starting characteristic.
J.!Enclosure Material:
1.!Use enclosure type as follows:
a.!Indoors: Totally enclosed, fan cooled (TEFC).
PLUMMER ASSOCIATES, INC. 40 05 93 - PAGE 4 OF 8 BID SET
0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
b.!Outdoors: Totally enclosed, fan cooled (TEFC), weatherproof.
c.!Division 1, Class 2 Areas: Provide motors totally enclosed, fan cooled,
explosion proof (TEFC-XP).
2.!TEFC motors shall have a steel or cast iron frame, cast iron end brackets, cast iron
conduit box, tapped drain holes (erosion resistant plug for frames 286T and smaller
and automatic breaker/drain devices for frame 324T and larger), and upgraded
insulation by additional dips and baked to increase moisture resistance.
2.6!POLYPHASE MOTORS WITH ADDITIONAL REQUIREMENTS
A.!Motors Used with Reduced-Voltage and Multispeed Controllers: Match wiring connection
requirements for controller with required motor leads. Provide terminals in motor terminal
box, suited to control method.
B.!Motors Used with Variable Frequency Controllers:
1.!Windings: Copper magnet wire with moisture-resistant insulation varnish, designed
and tested to resist transient spikes, high frequencies, and short time rise pulses
produced by pulse-width modulated inverters.
2.!Energy- and Premium-Efficient Motors: Class B temperature rise; Class F insulation.
3.!Inverter-Duty Motors: Class F temperature rise; Class H insulation.
4.!Thermal Protection: Comply with NEMA MG 1 requirements for thermally protected
motors.
5.!Shall include an insulated bearing opposite the drive end and shall include shaft
grounding as manufactured by AEGIS.
C.!Severe-Duty Motors: Comply with IEEE P841, with 1.15 minimum service factor.
2.7!NAMEPLATES
A.!Main Nameplate: Provide each motor with a stainless steel name-plate meeting the
requirements of NEMA MG 1, and the National Electrical Code.
B.!Heater Nameplate: When space heaters are furnished, include voltage and wattage on a
suitable nameplate.
C.!Bearings Nameplate: When bearings are oil lubricated, include oil type information on a
suitable nameplate. Also, indicate bearing data if nonstandard.
D.!Attachment: Attach the nameplates to the motor with stainless steel fastening pins or
screws.
2.8!CONDUIT BOX
A.!Provide each motor not supplied with a cord and plug with a conduit box amply dimensioned
for the motor lead terminations. Include a grounding lug on motors 1/6 horsepower and
larger. Supply a gasket suitable for the motor enclosure type and application.
2.9!SPACE HEATERS
A.!Provide space heaters in all motors.
B.!Use heaters hermetically sealed in stainless steel or equivalent corrosion-resistant sheaths.
C.!Rate heaters 115 volts, 60 hertz.
D.!Braze heat-resistant insulated leads to the heater or supply heater with brazed leads and
extend to the conduit box.
E.!Size heaters according to the horsepower size as follows:
1.!3/4 - 50 horsepower 100 watts
2.!60-125 horsepower 150 watts
3.!150-200 horsepower 200 watts
PLUMMER ASSOCIATES, INC. 40 05 93 - PAGE 5 OF 8 BID SET
0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
2.10!MONITORING DEVICES
A.!All motors 20 HP and above and motors driven by variable frequency drives shall be
equipped with three (3) normally open PTC thermistors, wired in parallel.
2.11!GROUNDING CONNECTIONS
A.!Ground provisions shall be furnished per NEMA M91.
B.!For motors less than 10HP, each motor shall be furnished with provision for attaching a
ground connection to the motor frame inside the motor terminal housing.
2.12!LEADS
A.!For motor leads, use not less than ASTM B 173, Class G, stranded copper conductors with
insulation the same as or better than specified in the preceding Motor Insulation paragraph.
B.!Provide permanent identification numbers on leads according to NEMA MG 1-2.02.
C.!Use crimp-on, solderless tinned copper terminals on leads and place heat-shrink insulation
sleeves or covers between leads and terminals.
2.13!ADDITIONAL REQUIREMENTS FOR VERTICAL MOTORS
A.!Solid shaft vertical motors are acceptable for all applications except when the connection to
the driven equipment consists of sectional driven shaft which may unscrew and lengthen
with direction reversal.
B.!Hollow-shaft vertical motors are acceptable for all applications when the thrust is in the
direction to engage the coupling.
C.!Hollow-shaft vertical motors coupled to a sectional drive shaft with screwed joints shall have
special couplings described as follows:
1.!Provide motors, except the explosion-proof type, with self-releasing couplings
designed to disconnect motor from driven equipment and permit lengthening of drive
shaft upon reversal of rotation.
2.!Provide explosion-proof motors with non-reversing couplings of spark-resisting
construction, designed to prevent reverse rotation.
D.!Design vertical motor thrust bearings conservatively to carry maximum axial thrusts (up and
down) imposed by driven equipment.
E.!Vertical motors shall have grease or oil-lubricated bearings at both top and bottom.
F.!Vertical motor bases shall be NEMA Type P.
G.!Provide hollow shaft vertical motors with a positive, non-reversing, corrosion-resistant (anti-
ratchet) mechanism.
H.!Provide vertical motors with fan-end splash shields.
2.14!POWER FACTOR CORRECTION CAPACITORS
A.!Linear Loads
1.!All single speed motors over 5 horsepower (from variable frequency drives), if
indicated on the Drawings, shall be provided with a heavy duty industrial type power
factor correction capacitor selected, recommended and furnished by the motor
manufacturer to raise the motor power factor to approximately 95 percent. For non-
explosion-proof motors, the capacitor shall be mounted on the equipment base plate
adjacent to the motor and shall be connected to the motor junction box with liquid
tight flexible conduit. For explosion-proof motors, the capacitors shall be wall
mounted in a non-hazardous area.
2.!Capacitors shall be dry film or liquid insulated and shall be hermetically sealed in steel
enclosures.
PLUMMER ASSOCIATES, INC. 40 05 93 - PAGE 6 OF 8 BID SET
0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
3.!Each capacitor unit shall be furnished with three high interrupting capacity current
limiting fuses. Fuses shall be equipped with "blown-fuse" indicators.
4.!Capacitor enclosures shall be suitable for conduit connection. Covers shall be
gasketed, bolt-on type.
5.!Capacitors shall be UL listed.
6.!Capacitors shall be by General Electric Co.; Square D Co. or equal.
B.!Alternate Power Factor Correction Equipment (Non-Linear Loads)
1.!Units shall be designed to provide power factor correction in applications subject to
the effects of harmonics.
2.!Units shall consist of power factor correction capacitors equipped with series
inductors. The units shall be tuned to just below the 5th harmonic frequency on
systems with predominately 3 Phase loads.
3.!Capacitors shall be NEMA rated and tested, shall be non-PCB dielectric,
biodegradable, low toxicity, equipped with current limiting fuses, internal discharge
resistors and fuse loss indicators. Fuses shall be capable of interrupting a short circuit
of 100,000 Amps at 480 Volts, 3 Phase.
C.!Inductors shall have low flux density and distributed gaps, copper windings, brazed
connections, winding varnish impregnated and baked, Class 220°C insulation with 80°C rise.
2.15!SINGLE-PHASE MOTOR
A.!Motors 1/6 Through 1/2 Horsepower: Provide single-phase NEMA Design N, squirrel cage
induction motors
B.!Motors Smaller Than 1/6 Horsepower: Provide single-phase squirrel cage induction motors
with integral thermal protectors.
PART 3 - EXECUTION
3.1!INSTALLATION
A.!The CONTRACTOR shall make all electrical connections to equipment specified. Installation
shall be made in compliance with manufacturer's recommendations and the Drawings. If
the Drawings or shop drawings and recommendations from the Manufacturer are not
available then installation shall proceed according to the best electrical industry and trade
practice.
B.!Properly install and align motors in the locations shown, except motors which are factory
mounted on the driven equipment. When the motor and equipment are installed, the name-
plate must be in full view.
C.!Testing Agency: Engage a qualified testing and inspecting agency to perform the following
field tests and inspections and prepare test reports.
3.2!PERFORM THE FOLLOWING FIELD TESTS AND INSPECTIONS AND PREPARE TEST REPORTS
A.!Perform each electrical test and visual and mechanical inspection, stated in NETA ATS
parameters.
3.3!MOTOR DATA SHEET
A.!.
END OF SECTION
PLUMMER ASSOCIATES, INC. 40 05 93 - PAGE 7 OF 8 BID SET
0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
ELECTRICAL MOTOR DATA SHEET
Manufacturer: _______ Model: ______ HP: _______________
Motor
Service: ______________________ Starting Conditions:___________________
Frame: ______________________ Enclosure: ___________________________
Voltage: __________ Phases:________ RPM:____________ Hertz:_________
Insulation Class:_____________________________ Duty:________________
Full Load AMPS: ____________________ No. Load AMPS:____________
Locked Rotor AMPS: _______________ Locked Rotor Time:_____________
Locked Rotor Torque: _____________ % Breakdown Torque:__________%
NEMA Design: ___________________ Service Factor: _________________
Number of Consecutive Starts: _________Hot: ____________Cold:_________
Full Load Temp Rise, degrees C over 40 degrees C Ambient
(at 1.0 S.F.):__________________________________________________
Service Factor Temp Rise, degrees C over 40 degrees C
(at 1.15 S.F.):_________________________________________________
Drive System: ________V-Belt _______Direct Coupled _______Gear Unit
Bearings: Type:______________ Life:____________ Lubrication:_______
Shaft: Size____________
Efficiency: Power Factor: Current:
1.15 S.F. Load: ___________ ______________ ___________
4/4 Load: _____________ ______________ ___________
3/4 Load: _____________ ______________ ___________
1/2 Load: _____________ ______________ ___________
Monitoring
Devices: ____ RTD's ______ Vibration Sensors ___________Thermistors
Main Motor Leads, size hole___________ Space Heater: __________KW
Ground Lug Size____________ Surge Protection: _______________
Blank spaces are to be completed by manufacturer.
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0537-038-01 COMMON MOTOR REQUIREMENTS FOR PROCESS EQUIPMENT JANUARY 2023
SECTION 40 41 13
PROCESS PIPINGHEAT TRACING
GENERAL
1.1SUMMARY
Furnish all labor, materials, equipment and incidentals required to design, furnish and install
electrical heat trace systems on the piping as shown on the Drawings and as specified
herein.
The manufacturer shall design and supply the entire heating system, including the schematic
arrangements, heating cable, junction boxes, thermostats and other equipment necessary to
complete the system, as shown on the Drawings, and as specified herein.
The Engineer's piping drawings, piping line list, equipment list, instrument list and insulation
schedule constitute, in conjunction with this Section, the design parameters of the heat
tracing system. The Drawings are intended only to give a general layout of the heat tracing
system. Circuit layouts are not intended to show the number of fittings, or other installation
details. Furnish all labor and materials necessary to install and place in satisfactory
operation, a complete electric heat tracing system, based on the actual piping installation,
the manufactures installation drawings, and recommendations for operating temperature
settings.
All air release valve piping that will remain constantly wet and that is installed outdoors shall
be heat traced. All pressure gauge piping installed outdoors shall be heat traced and
insulated.
Related Sections include but are not necessarily limited to:
Division 0 -Procurement and Contracting Requirements.
Division 1 -General Requirements.
Section 40 42 13 "Process Piping Insulation".
1.2REFERENCES
All products and components shown on the Drawings and listed in this specification shall be
designed and manufactured according to latest revision of the following standards (unless
otherwise noted):
NFPA 70 –National Electrical Code (NEC)
NFPA 70E –Standard for Electrical Safety in the Workplace
American National Standards Institute (ANSI)
Institute of Electrical and Electronics Engineers (IEEE)
American Society for Testing and Materials (ASTM)
National Fire Protection Association (NFPA)
National Electric Code (NEC)
Factory Mutual (FM)
Underwriters Laboratories (UL)
National Electrical Manufacturers Association (NEMA)
Occupational Safety and Health Administration (OSHA)
Furnish copies of the necessary approvals for the heat tracing system and shall verify that
the approvals are current.
All equipment components and completed assemblies specified in this section of the
Specifications shall bear the appropriate label of Underwriters Laboratories.
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0537-038-01PROCESS PIPINGHEAT TRACINGJANUARY 2023
1.3SUBMITTALS
Shop Drawings:
In accordance with the procedures and requirements set forth in the General
Conditions and Section 01 33 00, "Submittal Procedures", Shop Drawings, Product
Data and Samples, the Contractor shall obtain from the equipment manufacturer and
submit the following:
Submittal data on all components of the heat trace system and any other data
recommended by the manufacturer.
Installation and maintenance instructions including, but not limited to:
Additional lengths of heat trace cable required for valves, flanges, pipe
supports, etc.
Orientation of heat trace cable on piping.
Installation of heat trace cable on nonmetallic pipe fully covered with foil
tape.
Power connection and termination of heat trace cable.
List of replacement parts for the entire system in table format.
Bill of materials list of the system as supplied in table format.
See Section 01 33 00, "Submittal Procedures"for requirements for the
mechanics and administration of the submittal process.
Product technical data:
Power requirements for each circuit based upon actual length of heat
trace and maintained temperature.
Circuit breaker rating based upon inrush current at minimum expected
start-up temperature.
Length of heat tape for each pipe size and run.
Coordinate and verify length and Watts/FT of heat tape required based
upon pipe size and insulation thickness.
Include the calculations to support the heat tape output.
Fabrication and/or layout drawings:
Wiring diagrams showing physical locations of thermostats and heat trace power
supply.
Contract Closeout Information:
Operation and Maintenance Data:
See Specification Section 01 78 23. "Operation and Maintenance Data"for
requirements for the mechanics, administration, and the content of Operation
and Maintenance Manual submittals.
1.4INFORMATIONAL SUBMITTALS:
See Specification Section 01 33 00, "Submittal Procedures"for requirements for the
mechanics and administration of the submittal process.
Test reports: Megger test results.
1.5QUALITY ASSURANCE
The manufacturer of this equipment shall have produced similar equipment for a minimum
period of five years. When requested by the Engineer, an acceptable list of installations with
similar equipment shall be provided demonstrating compliance with this requirement.
All heat tracing equipment furnished under this Section, shall be supplied by a single
manufacturer.
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0537-038-01PROCESS PIPINGHEAT TRACINGJANUARY 2023
All components and material shall be new and of the latest field proven design and in
current production. Obsolete components or components scheduled for immediate
discontinuation shall not be used.
1.6DELIVERY, STORAGE, AND HANDLING
Shall be stored such that they are not exposed to sunlight or other UV rays.
1.7WARRANTY
All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
PRODUCTS
2.1MANUFACTURERS
Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, are listed
below:
Thermon.
Chemelex Division; Raychem Corp.
Chromalox.
2.2HEAT TRACING
Design Parameters:
Pipe diameter, length and material: Unless otherwise stated on the Drawings, all wet
piping, exposed to the weather, 6inches and smaller shall be heat traced. See
Drawings and relevant piping Specifications.
Alum chemical feed piping shall not be heat traced.
Flange, valve, pipe support size: Unless otherwise stated on the Drawings, all wet
valves, exposed to the weather, 6inches and smaller shall be heat traced. See
Drawings and relevant piping Specifications.
Air Release Valves: Shall not be heat traced.
Pressure Gauges/Transmitters: Shall not be heat traced.
Pipe insulation type and thickness: See Drawings and Section 40 42 13 "Process
Piping Insulation".
Temperatures requirements:
Low ambient temperature for the specific location: minus 10-degree F.
Start-up temperature (alarm thermostat set point):
Water/wastewater lines: 40-degree F.
Chemical feed lines:40-degree F.
Caustic lines: 80-degree F.
Maintain temperature (power thermostat set point):
Water/wastewater lines: 40-degree F.
Chemical feed lines:40-degree F.
Caustic lines: 80-degree F.
High temperature exposure with power off: 185-degree F.
Wind factor for the specific location: 40 MPH.
Electrical requirements:
Voltage: 120 V.
Circuit breaker: Field coordinate if other than 20A GFEPCI type.
PLUMMER ASSOCIATES, INC.40 41 13-PAGE 3OF 6BIDSET
0537-038-01PROCESS PIPINGHEAT TRACINGJANUARY 2023
Safety factor: 10 percent.
Self-regulating or power-limiting parallel circuit construction consisting of an inner core of
conductive material between parallel copper bus wires, with inverse temperature -
conductivity characteristics with tinned copper metal overbraid.
Thermostats
Thermostats shall be ambient air sensing adjustable between 0 and 160 degree F
minimum with maximum differential range of 10 degree F, furnished complete with
NEMA 4 enclosures in all areas, 9/16-inch stainless steel sensor.
End Seal Signal Light Kit
NEMA 4Xrated end seal designed to power or seal one cable and indicate power on
with LED indicator light.
All necessary or required components and accessories, such as power connection boxes, end
seals, straps, tape and fitting brackets.
In noncorrosive and nonhazardous locations, insulation shall be Polyolefin.
In corrosive, hazardous and hydrocarbon locations insulation shall be Fluoropolymer
(Teflon).
EXECUTION
3.1PREPARATION
Examine surfaces and substrates to receive electric heating cables for compliance with
requirements for installation tolerances and other conditions affecting performance.
Ensure surfaces and pipes in contact with electric heating cables are free of burrs and sharp
protrusions.
Proceed with installation only after unsatisfactory conditions have been corrected.
All piping shall be pressure tested prior to installation of any heat tracing or insulation
components.
3.2INSTALLATION
Insulate and heat trace wet pipe systems as indicated on Drawings.
Install materials in accordance with manufacturer's instructions.
Each circuit shall not exceed the manufacturer's recommended maximum length.
For Metallic Piping:
Heat tracing shall be installed completely wired.
Cut heat trace to lengths as required and secure to pipe with glass or polyester fiber
tape.
For Nonmetallic Piping:
Allow for extra heat trace output because nonmetallic pipe has a lower heat transfer.
Heat tracing shall be installed completely wired.
Cut heat trace to lengths as required and secure to pipe with aluminum tape through
out the length of the trace.
Protection and Control Requirements:
Protection by a GFEPCI circuit breaker.
Breaker amperage rating shall be coordinated with Contractor when different than the
Contract Drawings.
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0537-038-01PROCESS PIPINGHEAT TRACINGJANUARY 2023
3.3TESTING
All heating cable shall be tested using a megohmeter (megger) between the heating cable
bus wires and the metallic ground braid. A 2,500 VDC megger test is required and the
minimum acceptable resistance value shall be 20 megaohms regardless of the circuitlength.
Any cables found to be less than this value shall be replaced at no additional cost to the
Owner. The megger tests shall be performed as follows:
After installation of the cable and all fabrication kits but prior to installing any of the
insulation system components.
After installation of the insulation system components but prior to energizing the
cables.
All test reading for each megger test shall be recorded by the installer and submitted
with the maintenance instructions.
Each length of heatingcable shall be documented including model, wattage, length of cable,
and process service description. After energizing the cables, voltage, current, and ambient
temperature shall be documented for each length of heating cable.
Contractor shall artificially lower the temperature reading of the RTD to initiate operation of
the heat trace system. Contractor shall confirm operation of the heat trace systems and field
test all available alarms.
END OF SECTION
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0537-038-01 PIPING SYSTEM, HEAT TRACING JANUARY 2023
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SECTION 40 42 13
PROCESS PIPINGINSULATION
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary Con-
ditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Section Includes:
Insulation Materials:
Cellular glass.
Flexible elastomeric.
Mineral fiber.
Adhesives, mastics, sealants, and tapes.
Factory-applied and field-applied jackets.
1.3SUBMITTALS
Product Data: For each type of product indicated.
Shop Drawings:
Detail application of protective shields, saddles, and inserts at hangers for each type
of insulation and hanger.
Detail attachment and covering of heat tracing inside insulation.
Detail insulation application at pipe expansion joints for each type of insulation.
Detail insulation application at elbows, fittings, flanges, valves, and specialties for
each type of insulation.
Detail removable insulation at piping specialties, equipment connections, and access
panels.
Detail application of field-applied jackets.
Detail application at linkages of control devices.
Detail field application for each equipment type.
Manufacturer’s warranty for products indicated.
1.4QUALITY ASSURANCE
Fire-Test-Response Characteristics: Insulation and related materials shall have fire-test-
response characteristics indicated, as determined by testing identical products per
ASTME84, by a testing and inspecting agency acceptable to authorities having jurisdiction.
Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement mate-
rial containers, with appropriate markings of applicable testing and inspecting agency.
Insulation Installed Indoors: Flame-spread index of 25 or less, and smoke-developed
index of 50 or less.
Insulation Installed Outdoors: Flame-spread index of 75 or less, and smoke-
developed index of 150 or less.
1.5DELIVERY, STORAGE, AND HANDLING
Deliver insulation, coverings, cements, adhesive, and coatings to site in containers with
manufacturer's stamp or label, affixed showing fire hazard indexes of products.
Protect insulation against dirt, water, and chemical and mechanical damage. Do not install
damaged or wet insulation; remove from project site.
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PRODUCTS
2.1INSULATION MATERIALS
General Requirements:
Products shall not contain asbestos, lead, mercury, or mercury compounds.
Products that come in contact with stainless steel shall have a leachable chloride con-
tent of less than 50 ppm when tested according to ASTMC871.
Insulation materials for use on austenitic stainless steel shall be qualified as accepta-
ble according to ASTMC795.
Foam insulation materials shall not use CFC or HCFC blowing agents in the manufac-
turing process.
Cellular Glass: Inorganic, incombustible, foamed or cellulated glass with annealed, rigid,
hermetically sealed cells.
Products: Subject to compliance with requirements, available products that may be
incorporated into the Work include, but are not limited to, the following:
Cell-U-Foam Corporation; Ultra-CUF.
Pittsburgh Corning Corporation; Foamglas SuperK.
Block Insulation: ASTMC552, TypeI.
Special-Shaped Insulation: ASTMC552, TypeIII.
Board Insulation: ASTMC552, TypeIV.
Preformed Pipe Insulation with Factory-Applied ASJ-SSL: Comply with ASTMC552,
TypeII, Class2.
Factory fabricatedshapes according to ASTMC450 and ASTMC585.
Flexible Elastomeric: Closed-cell, sponge-or expanded-rubber materials. Comply with
ASTMC534, TypeI for tubular materials and TypeII for sheet materials.
Products: Subject to compliance with requirements, available products that may be
incorporated into the Work include, but are not limited to, the following:
Aeroflex USA Inc.; Aerocel.
Armacell LLC; AP Armaflex.
RBX Corporation; Insul-Sheet1800 and Insul-Tube180.
Mineral-Fiber, Preformed Pipe Insulation:
Products: Subject to compliance with requirements, available products that may be
incorporated into the Work include, but are not limited to, the following:
Fibrex Insulations Inc.; Coreplus1200.
Johns Manville; Micro-Lok.
Knauf Insulation; 1000Pipe Insulation.
Manson Insulation Inc.; Alley-K.
Owens Corning; Fiberglas Pipe Insulation.
TypeI, 850 degFMaterials: Mineral or glass fibers bonded with a thermosetting res-
in. Comply with ASTMC547, TypeI, GradeA, with factory-applied ASJ-SSL.
2.2INSULATING CEMENTS
Mineral-Fiber, Hydraulic-Setting Insulating and Finishing Cement: Comply with
ASTMC449/C449M.
2.3ADHESIVES
Materials shall be compatible with insulation materials, jackets, and substrates and for bond-
ing insulation to itself and to surfaces to be insulated. Adhesive shall be as recommended by
the supplier of the insulation and jacket materials.
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2.4MASTICS
Materials shall be compatible with insulation materials, jackets, and substrates; comply with
MIL-C-19565C, TypeII, and as recommended by insulation supplier.
Vapor-Barrier Mastic: Water based; suitable for indoor and outdoor use on below ambient
services.
Water-Vapor Permeance: ASTME96, ProcedureB, 0.013 permat 43-mildry film
thickness.
Service Temperature Range: Minus 20 to plus 180 degF.
Solids Content: ASTMD1644, 59 percent by volume and 71 percent by weight.
Color: White.
2.5SEALANTS
Joint Sealants:
Joint sealants shall be as recommended by pipe insulation supplier and the Materials
shall be compatible with insulation materials, jackets, and substrates.
Permanently flexible, elastomeric sealant.
Service Temperature Range: Minus 100 to plus 300 degF.
Color: White or gray.
ASJ Flashing Sealants, and Vinyl, PVDC, and AluminumJacket Flashing Sealants:
Materials shall be compatible with insulation materials, jackets, and substrates.
Fire-and water-resistant, flexible, elastomeric sealant.
ServiceTemperature Range: Minus 40 to plus 250 degF.
Color: White.
2.6FACTORY-APPLIED JACKETS
Insulation system schedules indicate factory-applied jackets on various applications. When
factory-applied jackets are indicated, comply with the following:
ASJ: White, kraft-paper, fiberglass-reinforced scrim with aluminum-foil backing; com-
plying with ASTMC1136, TypeI.
ASJ-SSL: ASJ with self-sealing, pressure-sensitive, acrylic-based adhesive covered by
a removable protective strip; complying with ASTMC1136, TypeI.
2.7FIELD-APPLIED JACKETS
Field-applied jackets shall comply with ASTMC921, TypeI, unless otherwise indicated.
Aluminum Jacket: Comply with ASTMB209, Alloy3003, 3005, 3105 or 5005, TemperH-14.
Minimum Thickness:
Outdoors:0.024 inches.
Indoors: 0.016
Finish: Stucco-embossed.
Moisture Barrier for Indoor Applications: 1-mil-thick, heat-bonded polyethylene and
Kraftpaper.
Moisture Barrier for Outdoor Applications: 3-mil-thick, heat-bonded polyethylene and
Kraftpaper or 2.5-mil-thick Polysurlyn.
Factory-Fabricated Fitting Covers:
Same material, finish, and thickness as jacket.
Preformed 2-piece or gore, 45-and 90-degree, short-and long-radius elbows.
Tee covers.
Flange and union covers.
End caps.
Beveled collars.
Valve covers.
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Field fabricate fitting covers only if factory-fabricated fitting covers are not
available.
Underground Direct-Buried Jacket: 125-mil-thick vapor barrier and waterproofing mem-
brane consisting of a rubberized bituminous resin reinforced with a woven-glass fiberor pol-
yester scrim and laminated aluminum foil.
2.8ACCESSORIES
Tapes supplied with products per manufacturers recommendations.
Securements: Aluminum bands, insulations pins and hangers, staples, wire, corner angles
and related components supplied with products per manufacturers recommendations.
EXECUTION
3.1PREPARATION
Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that
will adversely affect insulation application.
Coordinate insulation installation with the trade installing heat tracing. Comply with re-
quirements for heat tracing that appliesto insulation.
Mix insulating cements with clean potable water; if insulating cements are to be in contact
with stainless-steel surfaces, use demineralized water.
3.2GENERAL INSTALLATION REQUIREMENTS
Install insulation materials, accessories, and finishes with smooth, straight, and even surfac-
es; free of voids throughout the length of equipment and piping including fittings, valves,
and specialties.
Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses re-
quired for each item of equipment and pipe system as specified in insulation system sched-
ules.
Install accessories compatible with insulation materials and suitable for the service. Install
accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet
or dry state.
Install insulation with longitudinal seams at top and bottom of horizontal runs.
Install multiple layers of insulation with longitudinal and end seams staggered.
Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties.
Keep insulation materials dry during application and finishing.
Install insulation with tight longitudinal seams and end joints. Bond seams and joints with
adhesive recommended by insulation material manufacturer.
Install insulation with least number of joints practical.
Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hang-
ers, supports, anchors, and other projections with vapor-barrier mastic.
Install insulation continuously through hangers and around anchor attachments.
For insulation application where vapor barriers are indicated, extend insulation on an-
chor legs from point of attachment to supported item to point of attachment to struc-
ture. Taper and seal ends at attachment to structure with vapor-barrier mastic.
Install insert materials and install insulation to tightly join the insert. Seal insulation
to insulation inserts with adhesive or sealing compound recommended by insulation
material manufacturer.
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Cover inserts with jacket material matching adjacent pipe insulation. Install shields
over jacket, arranged to protect jacket from tear or puncture by hanger, support, and
shield.
Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and
wet and dry film thicknesses.
Install insulation with factory-applied jackets as follows:
Draw jacket tight and smooth.
Cover circumferential joints with 3-inch-wide strips, of same material as insulation
jacket. Secure strips with adhesive and outward clinching staples along both edges of
strip, spaced 4 incheso.c.
Overlap jacket longitudinal seams at least 1-1/2 inches. Install insulation with longi-
tudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap.
Staple laps with outward clinching staples along edge at 2 incheso.c.
For below ambient services, apply vapor-barrier mastic over staples.
Cover joints and seams with tape as recommended by insulation material manufac-
turer to maintain vapor seal.
Where vapor barriers are indicated, apply vapor-barrier mastic on seams and joints
and at ends adjacent to pipe flanges and fittings.
Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nom-
inal thickness.
Finish installation with systems at operating conditions. Repair joint separations and crack-
ing due to thermal movement.
Repair damaged insulation facings by applying same facing material over damaged areas.
Extend patches at least 4 inchesbeyond damaged areas. Adhere, staple, and seal patches
similar to butt joints.
For above ambient services, do not install insulation to the following:
Vibration-control devices.
Testing agency labels and stamps.
Nameplates and data plates.
Manholes.
Handholes.
Cleanouts.
3.3PENETRATIONS
Insulation Installation at Roof Penetrations: Install insulation continuously through roof
penetrations.
Seal penetrations with flashing sealant.
For applications requiring only indoor insulation, terminate insulation above roof sur-
face and seal with joint sealant. For applications requiring indoor and outdoor insula-
tion, install insulation for outdoor applications tightly joined to indoor insulation ends.
Seal joint with joint sealant.
Extend jacket of outdoor insulation outside roof flashing at least 2 inchesbelow top of
roof flashing.
Seal jacket to roof flashing with flashing sealant.
Insulation Installation at Underground Exterior Wall Penetrations: Terminate insulation flush
with sleeve seal. Seal terminations with flashing sealant.
Insulation Installation at Aboveground Exterior Wall Penetrations: Install insulation continu-
ously through wall penetrations.
Seal penetrations with flashing sealant.
For applications requiring only indoor insulation, terminate insulation inside wall sur-
face and seal with joint sealant. For applications requiring indoor and outdoor insula-
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tion, install insulation for outdoor applications tightly joined to indoorinsulation ends.
Seal joint with joint sealant.
Extend jacket of outdoor insulation outside wall flashing and overlap wall flashing at
least 2 inches.
Seal jacket to wall flashing with flashing sealant.
Insulation Installation at Interior Wall and Partition Penetrations (That Are Not Fire Rated):
Install insulation continuously through walls and partitions.
Insulation Installation at Fire-Rated Wall and Partition Penetrations: Install insulation con-
tinuously through penetrations of fire-rated walls and partitions.
Comply with requirements in Section07 84 13"Penetration Firestopping" for firestop-
ping and fire-resistive joint sealers.
Insulation Installation at Floor Penetrations:
Pipe: Install insulation continuously through floor penetrations.
Seal penetrations through fire-rated assemblies.
3.4GENERAL PIPE INSULATION INSTALLATION
Requirements in this article generally apply to all insulation materials except where more
specific requirements are specified in various pipe insulation material installationarticles.
Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions:
Install insulation over fittings, valves, strainers, flanges, unions, and other specialties
with continuous thermal and vapor-retarder integrity, unless otherwise indicated.
Do not insulate flexible pipe couplings and expansion joints.
Insulate pipe elbows using preformed fitting insulation or mitered fittings made from
same material and density as adjacent pipe insulation. Each piece shall be butted
tightly against adjoining piece and bonded with adhesive. Fill joints, seams, voids,
and irregular surfaces with insulating cement finished to a smooth, hard, and uniform
contour that is uniform with adjoining pipe insulation.
Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of
same material and thickness as used for adjacent pipe. Cut sectional pipe insulation
to fit. Butt each section closely to the next and hold in place with tie wire. Bond
pieces with adhesive.
Insulate valves usingpreformed fitting insulation or sectional pipe insulation of same
material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe in-
sulation by not less than two times the thickness of pipe insulation, or one pipe diam-
eter, whichever is thicker. For valves, insulate up to and including the bonnets, valve
stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with in-
sulating cement.
Insulate strainers using preformed fitting insulation or sectional pipe insulation of
same material, density, and thickness as used for adjacent pipe. Overlap adjoining
pipe insulation by not less than two times the thickness of pipe insulation, or one pipe
diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulat-
ing cement. Insulate strainers so strainer basket flange or plug can be easily re-
moved and replaced without damaging the insulation and jacket. Provide a remova-
ble reusable insulation cover. For below ambient services, provide a design that
maintains vapor barrier.
Insulate flanges and unions using a section of oversized preformed pipe insulation.
Overlap adjoining pipe insulation by not less than two times the thickness of pipe in-
sulation, or one pipe diameter, whichever is thicker.
Cover segmented insulated surfaces with a layer of finishing cement and coat with a
mastic. Install vapor-barrier mastic for below ambient services and a breather mastic
for above ambient services. Reinforce the mastic with fabric-reinforcing mesh.
Trowel the mastic to a smooth and well-shaped contour.
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For services not specified to receive a field-applied jacket except for flexible elasto-
meric and polyolefin, install fitted aluminumcover over elbows, tees, strainers, valves,
flanges, and unions. Terminate ends with aluminumend caps. Tape aluminumco-
vers to adjoining insulation facing using aluminumtape.
Stencil or label the outside insulation jacket of each union with the word "UNION."
Match size and color of pipe labels.
Insulate instrument connections for thermometers, pressure gages, pressure temperature
taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes,
vessels, and equipment. Shape insulation at these connections by tapering it to and around
the connection with insulating cement and finish with finishing cement, mastic, and flashing
sealant.
Install removable insulation covers at locations indicated. Installation shall conform to the
following:
Make removable flange and union insulation from sectional pipe insulation of same
thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe
insulation.
When flange and union covers are made from sectional pipe insulation, extend insula-
tion from flanges or union long at least twotimes the insulation thickness over adja-
cent pipe insulation on each side of flange or union. Secure flange cover in place with
stainless-steel or aluminum bands. Select band material compatible with insulation
and jacket.
Construct removable valve insulation covers in same manner as for flanges except di-
vide the two-part section on the vertical center line of valve body.
When covers are made from block insulation, make two halves, each consisting of mi-
tered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached
insulation, to flanges with tie wire. Extend insulation at least 2 inchesover adjacent
pipe insulation on each side of valve. Fill space between flange or union cover and
pipe insulation with insulating cement. Finish cover assembly with insulating cement
applied in two coats. After first coat is dry, apply and trowel second coat to a smooth
finish.
Finish exposed surfaces with an aluminumjacket.
3.5CELLULAR-GLASS INSULATION INSTALLATION
Insulation Installation on Straight Pipes and Tubes:
Secure each layer of insulation to pipe with wire or bands and tighten bands without
deforming insulation materials.
Where vapor barriers are indicated, seal longitudinal seams, end joints, and protru-
sions with vapor-barrier mastic and joint sealant.
For insulation with factory-applied jackets on above ambient services, secure laps
with outward clinched staples at 6 incheso.c.
For insulation with factory-applied jackets on below ambient services, do not staple
longitudinal tabs but secure tabs with additional adhesive as recommended by insula-
tion material manufacturer and seal with vapor-barrier mastic and flashing sealant.
Insulation Installation on Pipe Flanges:
Install preformed pipe insulation to outer diameter of pipe flange.
Make width of insulation section same as overall width of flange and bolts, plus twice
the thickness of pipe insulation.
Fill voids between inner circumference of flange insulation and outer circumference of
adjacent straight pipe segments with cut sections of cellular-glass block insulation of
same thickness as pipe insulation.
Install jacket material with manufacturer's recommended adhesive, overlap seams at
least 1 inch, and seal joints with flashing sealant.
Insulation Installation on Pipe Fittings and Elbows:
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Install preformed sections of same material as straight segments of pipe insulation
when available. Secure according to manufacturer's written instructions.
When preformed sections of insulation are not available, install mitered sections of
cellular-glass insulation. Secure insulation materials with wire or bands.
Insulation Installation on Valves and Pipe Specialties:
Install preformed sections of cellular-glass insulation to valve body.
Arrange insulation to permit access to packing and to allow valve operation without
disturbing insulation.
Install insulation to flanges as specified for flange insulation application.
3.6FLEXIBLE ELASTOMERIC INSULATION INSTALLATION
Seal longitudinal seams and end joints with manufacturersrecommended adhesive to elimi-
nate openings in insulation that allow passage of air to surface being insulated.
Insulation Installation on Pipe Flanges:
Install pipe insulation to outer diameter of pipe flange.
Make width of insulation section same as overall width of flange and bolts, plus twice
the thickness of pipe insulation.
Fill voids between inner circumference of flange insulation and outer circumference of
adjacent straight pipe segments with cut sections of sheet insulation of same thick-
ness as pipe insulation.
Secure insulation to flanges and seal seams with manufacturersrecommended adhe-
sive to eliminate openings in insulation that allow passage of air to surface being insu-
lated.
Insulation Installation on Pipe Fittings and Elbows:
Install mitered sections of pipe insulation.
Secure insulation materials and seal seams with manufacturer's recommended adhe-
sive to eliminate openings in insulation that allow passage of air to surface being insu-
lated.
Insulation Installation on Valves and Pipe Specialties:
Install preformed valve covers manufactured of same material as pipe insulation when
available.
When preformed valve covers are not available, install cut sections of pipe and sheet
insulation to valve body. Arrange insulation to permit access to packing and to allow
valve operation without disturbing insulation.
Install insulation to flanges as specified for flange insulation application.
Secure insulation to valves and specialties and seal seams with manufacturer's rec-
ommended adhesive to eliminate openings in insulation that allow passage of air to
surface being insulated.
3.7MINERAL-FIBER INSULATION INSTALLATION
Insulation Installation on Straight Pipes and Tubes:
Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten
bands without deforming insulation materials.
Where vapor barriers are indicated, seal longitudinal seams, end joints, and protru-
sions with vapor-barrier mastic and joint sealant.
For insulation with factory-applied jackets on above ambient surfaces, secure laps
with outward clinched staples at 6 inches(150 mm)o.c.
For insulation with factory-applied jackets on below ambient surfaces, do not staple
longitudinal tabs but secure tabs with additional adhesive as recommended by insula-
tion material manufacturer and seal with vapor-barrier mastic and flashing sealant.
Insulation Installation on Pipe Flanges:
Install preformed pipe insulation to outer diameter of pipe flange.
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Make width of insulation section same as overall width of flange and bolts, plus twice
the thickness of pipe insulation.
Fill voids between inner circumference of flange insulation and outer circumference of
adjacent straight pipe segments with mineral-fiber blanket insulation.
Install jacket material with manufacturer's recommended adhesive, overlap seams at
least 1 inch(25 mm), and seal joints with flashing sealant.
Insulation Installation on Pipe Fittings and Elbows:
Install preformed sections of same material as straight segments of pipe insulation
when available.
When preformed insulation elbows and fittings are not available, install mitered sec-
tions of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insu-
lation materials with wire or bands.
Insulation Installation on Valves and Pipe Specialties:
Install preformed sections of same material as straight segments of pipe insulation
when available.
When preformed sections are not available, install mitered sections of pipe insulation
to valve body.
Arrange insulation to permit access to packing and to allow valve operation without
disturbing insulation.
Install insulation to flanges as specified for flange insulation application.
3.8FIELD-APPLIED JACKET INSTALLATION
Install with 2-inchoverlap at longitudinal seams and end joints. Overlap longitudinal seams
arranged to shed water. Seal end joints with weatherproof sealant recommended by insula-
tion manufacturer. Secure jacket with stainless-steel bands 12 incheso.c. and at end joints.
Install aluminum jackets on exterior above grade piping and fittings and on interior
piping insulated using cellular-glass.
3.9FINISHES
Do not field paint aluminum or stainless-steel jackets.
3.10PIPING INSULATION SCHEDULE
General Requirements:
Acceptable preformed pipe and tubular insulation materials and thicknesses are iden-
tified for each piping system and pipe size range. If more than one material is listed
for a piping system, selection from materials listed is Contractor's option.
All exposed outdoor piping and piping installed in unheated vaults, 8inches in diame-
ter and smaller (Unless otherwise indicted on the Drawings) shall be insulated.
PIPE INSULATION SCHEDULE
Insulation Thickness
Pipe Diameter
(3)
(Inches)
FlowstreamInsulation Type
(Inches)
(2)
IndoorOutdoor
Instrument Sensing ----NA
(1)
Lines
Domestic Hot Water3/43/4Flexible Elastomeric
Domestic Cold Water1Flexible Elastomeric
Water and Waste Less than 2NA1-1/2Cellular-glass
WaterMineral Fiber
Water and Waste 2 to 6NA2Cellular-glass
WaterMineral Fiber
Water and Waste 8 to 12NA2Cellular-glass
WaterMineral Fiber
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Insulation Thickness
Pipe Diameter
(3)
(Inches)
FlowstreamInsulation Type
(Inches)
(2)
IndoorOutdoor
Vent, Air Release1 to 2NA1Flexible Elastomeric
Mineral Fiber
(4)
Blower Air PipingMineral Fiber
Sample1/2 to 1NA3/4Flexible Elastomeric
1. Instrument sense lines include tubing used for differential pressure measurements in venture flow
meters, pressure indicating devices, and other instruments.
2. Outdoor includes piping exposed to atmosphere; areas inside unheated vaults, utility corridors,
chases, etc.
3. When more than one insulation type named Contractor may select.
4. Apply insulation to hot blower discharge piping in accessible areas for personnel protection.
Heat Trace:
Provide heat tracing in accordance with Section40 41 13 “Process Piping Heat
Tracing”.
Size insulation to accommodate heat tracing cable
3.11INDOOR, FIELD-APPLIED JACKET SCHEDULE
Install jacket over insulation material. For insulation with factory-applied jacket, install the
field-applied jacket over the factory-applied jacket.
Piping, Concealed:
None.
Piping, Exposed:
Aluminum, Stucco Embossed: 0.016inchthick.
3.12OUTDOOR, FIELD-APPLIED JACKET SCHEDULE
Install jacket over insulation material. For insulation with factory-applied jacket, install the
field-applied jacket over the factory-applied jacket.If more than onematerial is listed, selec-
tion from materials listed is Contractor's option.
Piping:
Aluminum, Stucco Embossed with Z-Shaped Locking Seam: 0.024 inchthick.
END OF SECTION
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F:\\PROJECTS\\0537\\038-01\\9 DESIGN\\9-4 SPECIFICATIONS\\100%\\DIV 40\\40 42 13 PROCESS PIPING INSULATION.DOCX
SECTION 40 46 16
PROTECTIVE LIQUID LININGS AND COATINGSFOR SUBSTRATES
EXPOSED TOA CORROSIVE WASTEWATER ENVIRONMENT
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
“Exposed to corrosive wastewater environment”includes concreteor other substratesin
direct contact with wastewater,the gases produced by wastewaterin covered channels and
basins, and includesall interior substrate surfaces of wetwells, manholes,raw wastewater
screening and grit removal structures, wastewater flow equalization basinsand where
special coatings are requiredand shown in the drawings.
This Section includes the surface preparation and application of high-performance liquid
lining (coating)systems on the following substrates:
Concrete, both vertical and horizontal surfaces, exposed to corrosive gases and liquids
in a wastewater environment.
Protective coating system shall be applied at the Headworks effluent splitter boxes as shown
on the drawings. The extent of protective coating shall be located on the interior vertical and
horizontal substrates(including walls,floors, and ceilings).Coating shall not be applied on
surfaces indicated on the Drawings.
Surface preparation and coating application and thicknesses shall be as specified herein and
shall meet or exceed the manufacturer’s recommendations. When the manufacturer’s
minimum recommendations exceed the specified requirements, CONTRACTOR shall comply
with the Manufacturer’s minimum recommendations.
Related Sections:
Section 01 60 00“Product Requirements” for submittals.
Division 03Sectionsfor concrete structuresand grout.
Section 09 91 00“Painting and Protective Coatings” for substrate preparation.
Where walls are indicated to be coated and there is coverplate at the top of the wall, the
coating shall extend to the top of the concrete, including covering the plate supportledge.
1.3REFERENCES AND DEFINITIONS
Without limiting the general aspects of these specifications, all surface preparation, coating
and painting of substrate surfaces and inspection shall conform to the applicable
requirements of SSPC (Society for ProtectiveCoatings), NACE International, ASTM (American
Society for Testing and Materials), AWWA and the manufacturer's printed instructions.
References:
American Concrete Institute (ACI)
ACI 350 Code Requirements for Environmental Engineering Concrete Structures
and Commentary
ACI 515A Guide to the use of Waterproofing, Damproofing, Protective, and
Decorative Barrier Systems for Concrete
ACI 546 R Concrete Repair Guide
ACI 546.3 R Guide for the Selection of Materials for the Repair of Concrete
PLUMMER ASSOCIATES, INC.40 46 16-PAGE 1OF 12BIDSET
0537-038-01PROTECTIVE LIQUID LININGS AND COATINGS…JANUARY2023
American Society of Testing and Materials(ASTM)
ASTM C 868 Standard Test Method for Chemical Resistance of Protective
Linings
ASTM D 520Standard Specification for Zinc Dust Pigment
ASTM D2200 Standard Practice for Use of Pictorial Surface Preparation
Standards and Guides for Painting Steel Surfaces
ASTM D 4263 Standard Test Method for Indicating Moisture in Concrete by the
Plastic Sheet Method
ASTM D 4417Standard Test Methods for Field Measurement of Surface Profile
of Blast Cleaned Steel
ASTM D 4787 Standard Practice for Continuity Verification of Liquid or Sheet
Linings Applied to Concrete Substrates
ASTM D 5162 Standard Practice for Discontinuity (Holiday) Testing of
Nonconductive Protective Coating on Metallic Substrates
ASTM D 7088 Standard Practice for Resistance to Hydrostatic Pressure for
Coatings Used in Below Grade Applications Applied to Masonry
ASTM E 337Standard Practice Test Method for Measuring Humidity with a
Psychrometer
ASTM F 1869Standard Test Method for Measuring Moisture Vapor Emission
Rate of Concrete Subfloor Using Anhydrous Calcium Chloride
ASTM F 2414Standard Practice for Sealing Sewer Manholes Using Chemical
Grouting
ASTM D 4787 Continuity Verification of Liquid or Sheet Linings Applied to
Concrete Substrates
ASTM D 7234 Pull-Off Adhesion Strength of Coatings on Concrete Using
Portable Pull-Off Adhesion Testers
American National Standards Institute (ANSI): ANSI/ASC 29.4 Exhaust Systems
Abrasive Blasting Operations –Ventilation and Safe Practice
International Concrete Repair Institute (ICRI):Technical Guideline 03732 -Selecting
and Specifying Concrete Surface Preparation for Coatings, Sealers, and Polymer
Overlays
The Society for Protective Coatings (SSPC)
SSPC Painting Manual, “Good Painting Practice”
SSPC Painting Manual, “Systems and Specifications”
SSPC-SP1 Solvent Cleaning
SSPC-SP2 Hand Tool Cleaning
SSPC-SP3 Power Tool Cleaning
SSPC-SP5 White Metal Blasting
SSPC-SP6 Commercial Blast Cleaning
SSPC-SP7 Brush-Off Blast Cleaning
SSPC-SP10 Near-White Blast Cleaning
SSPC-SP12Surface Preparation and Cleaning of Metals by Waterjetting Prior to
Recoating
SSPC-SP13 Surface Preparation of Concrete
SSPC-PA-2 Measurement of Dry Film Thickness with Magnetic Gages
SSPC-PA-3 Guide to Safety in Paint Application
SSPC-Guide 12 Guide for Illumination of Industrial Painting Project
SSPC-SP14 Industrial Blast Cleaning
SSPC-VIS 1 89 Visual Standard for Abrasive Blast Cleaned Steel
Master Painters Institute (MPI): MPI Architectural Painting Specification Manual
NACE International (National Association of Corrosion Engineers International)
RP0287-95 “Field Measurements of Surface Profile of Abrasive Blast Cleaned
Steel Surfaces Using Replica Tape”
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0537-038-01PROTECTIVE LIQUID LININGS AND COATINGS…JANUARY2023
RP0288-94“Standard Recommended Practice, Inspection of Linings on Steel
and Concrete”
SP0188-99“Discontinuity (Holiday) Testing of Protective Coatings”
TM-01-70“Visual Comparator for Surfaces of New Steel Airblast Cleaned with
Sand Abrasive”
TM-01-70 “Visual Comparator for Surfaces of New Steel Airblast Cleaned with
Slag Abrasive”
SP0178-95 “Fabrication Details, Surface Finish Requirements, and Proper
Design Considerations for Tanks and Vessels to be Lined for Immersion
Service”
RPO 892-92 “Linings Over Concrete for Immersion Service”
RPO 591-96 “Coatings for Concrete Surfaces in Non-Immersion”
6G186 “Surface Preparation of Contaminated Steel Surfaces”
6G191“Surface Preparation of Contaminated Concrete.”
RPO 178 “Weld preparation Visual Comparator.”
RPO 188 –Holiday Testing
Definitions:
Barrier Coat: Recommended coating material applied to factory-applied or other
coatings, which consist of unidentified materials or non-compliance materials, prior to
the application of the specified coating system.
MDFT: Minimum Dry Film Thickness, mils.
MDFTPC: Minimum Dry Film Thickness per Coat, mils.
Mils: Thousandth of an Inch.
1.4SUBMITTALS
Action Submittals:
Product Data:
For each product, furnish a Product Data Sheet (PDS), the manufacturer’s
technical data sheets, and coating colors available. The PDS form can be found
atthe end of this Section.
Technical and performance information that demonstrates compliance with this
specification.
Indiscriminate submittal of only manufacturer’s literature is not acceptable.
Detail chemical and gradation analysis for each abrasive material.
Samples:
Proposed Abrasive Materials: Minimum 2-pound sample for each type.
Reference Panel:
Surface Preparation:
Prior to start of surface preparation, furnish a four-inch by four-
inch concrete and/or steel panelas appropriatefor grade of
sandblastand/or pressure washspecified herein, prepared to
specified requirements.
Provide panel representation of the concrete and steel to be
coated; prevent deterioration of surface quality.
Panel to be reference source for inspection upon approval by
ENGINEER.
Coating Samples for Verification: For each type of coating system
indicated:
Submit Samples on rigid backing, fourinchessquare.
Step coats on Samples to show each coat required for system.
Label each coat of each Sample.
Label each Sample for location and application area.
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Product List: For each product indicated, include the following:
Show where each coating is to be used on the Project, with cross
reference to this Section paragraphs.
Product date and information submitted shall demonstrate
compliance with this Section.
Provide the surface preparation required or recommended by
coating manufacturer for each typeof coating application if
different from that specified in this Section.
Information Submittals:
Applicator’s Qualifications:
Written certification from coating manufacturer indicating applicator is qualified
to apply specified coating.
Number of years ofexperience applying the specified coating.
List of references substantiating experience with the specified coating.
Provide Material Safety Data Sheets (MSDS) for review and posting at Site.
Coating manufacturer’s Certificate of Compliance.
Provide ENGINEER with certification from coating supplier that sufficient materials
have been purchased for Project.Certificate shall list the quantities and types of
coating purchased.
Provide ENGINEER with certification from the blast cleaning supplier that sufficient
materials have been purchased to provide for the surface preparation specified for
Project.Certificate shall list the quantities and gradation purchased.
Manufacturer’s written verification that submitted coating materials are suitable for
the intended use.
If the manufacturer of finish coating differs from that of primer, provide finish coating
manufacturer’s written confirmation that materials are compatible.
Manufacturer’s Information and Instructions:
Provide manufacturer’s instructions for the application of the coating system for
the purpose intended by these specifications. The instructions shall provideand
clearly statethe limitations, precautions, and requirements that may adversely
affect the coating system; that may cause unsatisfactorily results after the
application; or that may prevent the coating system from servingthe purpose
for which it was intended, which is to provide coverage and protection from
corrosion.
The instructions shall include, but notbelimited to:
Surface preparation.
Mixing requirements and coating window after mixing, and Methods of
Application.
Number of coatsof each type.
Thickness of each coat.
Total Thickness.
Drying time of each coat, including primer.
Drying time of final coat before placement in service.
Time allowed between coats.
Primers required to be used.
Primers not permitted.
Use of a primer.
Compatible topcoats.
Thinner and use of thinner.
Environmental conditions and weather limitations during andwithin cure
timeafter application (temperature,substrate moisture,humidity, wind
velocity).
Delivery, Storageand Handling procedures and requirements
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Physical properties of paint, including percent solids content by volume,
ingredient analysis, and weight per unit surface per dry mil thickness.
Cathodic disbonding limitations, if any.
Equipment settings (air cap, fluid tip, equipment pressure settings, etc.)
Repair Procedures
Field quality-control reports: Provide temperature and humidity readingsdaily before and
after coatings are applied,substrate moisture prior to coating,testing for coating dry mil
thickness and bonding, surface preparation, and related requirements.
Pre-installation Conference: Conduct with Owner, Engineerand Contractor. Provide minutes
of the pre-installation conference.
Warranty Certificatesfor each product indicated.
1.5PERFORMANCE CRITERIA
Protective coating products shall be capable of withstandingconstantand intermittent
exposure to raw wastewater, permeation from hydrogen sulfide and other sewer gases,
attack from organic acids generated by microbial sources,and chloride levels up to 2,000
mg/Lwith no adverse effects. Products must have sufficient field history and accelerated
laboratory testing to substantiate product viability for these exposures.
The protective coating on below grade structuresand in adjacent channels or basinsshall
not pull away from the substrate or rupture due to wastewater seepage through floors or
walls, or ground water seepage fromhydraulic pressure through cracks or imperfections in
the substrate. Coating manufacturer shall submit documentation that the coating can
withstand the hydraulic pressure at each application location.
1.6QUALITY ASSURANCE
Coating Manufacturer Qualifications: Company specializing in manufacturing quality coating
products with 10 years of experience.
Applicator Qualifications: Company specializing in concrete coating with five (5) years
documented experiencewith the specified product, approved by product manufacturer, and
shall provide proof before commencement of work that a qualified crew of applicators will be
maintained throughout the duration of the work.
Applicator shall submit documentation indicating the following:
Training of personnel in themeasurement of substrate environmental conditions and
proper surface preparation requirements.
Training of personnel in the proper storing, mixing, application, and inspection of the
coatings.
Training of personnel in health and safety practices.
Coating shall have at least fiveyears of satisfactory performancein similar applications.
Furnish reference location for coating(s)and system proposed.
CONTRACTOR shall coordinate materials to be coated to ensure compatibility for all
materials and coatings in this Section.
Coating system manufacturer shall review actual job conditions prior to purchase of any
materials. Manufacturer shall submit to ENGINEER a statement listing any exceptions to the
specifications regarding preparation requirements or coating applicability.
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CONTRACTOR shall receive written confirmation of the specificenvironmental conditions,
surface preparation procedures and coordination with primers used for all components to be
coatedto ascertain appropriate and manufacturer compatible finish coat materials to be
used before painting such work.
Comply with applicable provisions and recommendations of references listed in Paragraph
1.3 above.
1.7DELIVERY, STORAGE, AND HANDLING
Deliver, store, and protect products in accordance with manufacturer's instructions.
Deliver products to site in the original, sealed, labeled, and unopened containers; inspect to
verify acceptance. Damaged containers will not be accepted.
Container labeling to include manufacturer's name, brand name, type of paint or coating,
color designation, standard compliance, materials content, as well as instructionsfor mixing,
reducing, and applications requirements.
Store materials in original containers in a secure (lockable), dry, heated and well ventilated
single designation area meeting the minimum requirements of the paint manufacturer and
jurisdictional authorities and at minimum ambient temperatures continuously maintained at
not less than 45 º F (7 º C) and not more than 90 º F (32 º C).
Take precautionary measures to prevent fire hazards and spontaneous combustion. Remove
oily rags, waste, or other fire hazards from facilities each night. Place cloths and cotton
waste, which might constitute a fire hazard, in metal containers or destroy at the end of
each work day.
Comply with requirements of authorities having jurisdiction, in regard to the use, handling,
storage and disposal of hazardous materials.
1.8PROJECT CONDITIONS
Unless approved by ENGINEER and the coating manufacturer, perform no coating when the
ambient air temperature and substrate surface temperature are below 50 º F or above 95 º F.
Perform no coating work unless environmental conditions are within the coating
manufacturer’s requirements and adequate weather protection is provided. Where required,
suitable weatherproof covering and sufficient heating facilities shall be in place to maintain
minimum ambient air and surface temperatures for 24 hours before, during, and 24 hours
after application of coatings.
Perform no coating work unless adequate continuous ventilation and sufficient heating
facilities are in place to maintain minimum ambient air and surface temperatures. Provide
supplemental ventilating and heating equipment if ventilation and heating from an existing
system is inadequate to meet minimum requirements.
Perform no coating work when the relative humidity is above 85% or when the dew point is
less than 5 º F variance between the air/surface temperatures oris not per coating
manufacturer’s guidelines.
Perform no coating work when the maximum moisture content of the substrate exceeds
12% for concrete or is not per coating manufacturer’s guidelines.
Perform no coating work on concrete or masonry substrates untilthe existing coating
system has been removed and the existing concrete surface has been prepared per the
MANUFACTURER’s recommendations.
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Perform no coating work unless a minimum lighting level of 323 Lux (30-footcandles) is
provided on surfaces to be painted. Adequate lighting shall be furnished by CONTRACTOR.
Apply coating only to dry, clean, properly cured and adequately prepared surfaces in areas
where dust is no longer generated by construction activities such that airborne particles will
not affect the quality of finished surfaces.
Coating products of the same type shall be supplied by the same manufacturer. Do not mix
products from different sources.
CONTRACTOR shall be fully responsible for personnel safety during coating operations.
Display caution signs in necessary areas advising of spray coating and warning
against open flames.
Provide barriers or shelters on windy days to protect equipment and facilities.
Temporary ladders and scaffolds shall conform to applicable safety requirements.
1.9SPECIAL WARRANTY
Protective coating manufacturer shall warranty its products as free from material defects for
a minimum period of three (3) yearsfrom the date of Substantial Completion ofthe
structure/treatment unit. Provide associated Warranty Certificate.
Applicator shall warranty the installed protective coating system as free from workmanship
defects for a minimum period of three (3) yearsfrom the date of Substantial Completion of
the structure/treatment unit. Provide associated Warranty Certificate.
Warranty inspectionsof the coating system shall be conducted by theENGINEER and
thrdth
OWNER during the 11, 23and 35monthsfollowing completion and acceptance of all
coating system work. The personnel or their representatives present at the pre-installation
conference are requested to attend. All defective coating systems shall be repaired in
accordance with this Section and to the satisfaction of the ENGINEER and OWNER.
PRODUCTS
2.1MANUFACTURERS
Nationally recognized manufacturers of protective coatings who are regularly engaged in the
production of such materials for essentially identical service conditions.Manufacturers shall
have a minimum of 10years verifiable experience in manufacture of specified product.
Acceptable Manufacturers: Provide coating products from one of the manufacturers listed
below:
Raven
Primer: Raven 155or 171 Series at 4-6 mils
TopCoat: Raven 405 Series, 250 mils
Chesterton
Walls and floor: ARC 791, 250 mils
Ceiling: S1HB, 125 mils
2.2COATING PRODUCTS
General:
Coating manufacturer’s highest quality products suitable for intended service.
All materials shall be from a single manufacturer for eachcoating system used.
CONTRACTOR shall provide all accessory components such as polysulfide sealants,
and curing compounds, as recommended by the manufacturer for maximum
protective lining adhesion to substrate, and long-term service performance.
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CONTRACTOR shall have complete responsibility for ensuring that each coating applied is
compatible with its substrate and/or its intended finish coat, and that the completed coating
system is suitable for its intended service.
Accessory Materials: Thinning of coatings and all accessory type materials used shall be in
accordance with the manufacturer's recommendations covering material types, solvents, mix
ratios, and methods.
Minimum Coating Requirements
Primer Coat: Coating systems may require a primer coat to prevent out-gassing
through intermediate and topcoats. A primer coat must be applied on concrete
2
exhibiting a moisture vapor emission rate greater than 3 lb/1000 ft/24 hours as
tested according to ASTM F 1869. The electrical conductivity of concrete itself may be
successfully used for high-voltage continuity testing of linings applied directly with no
specific conductive underlayment installed.
Top Coatmust meet the following requirements:
Finish shall be corrosion resistant toHydrogen Sulfide; 20% Sulfuric Acid; 1%
Nitric Acid; 5% Sodium Hydroxide; and up to 6,000 mg/L chlorides.
Must be compatible with and of a similar material as primer coat.
Finish Coat: A finish coat is only required if it is a standard product of the overall
coating system and if the intermediate coat does not provide a high abrasion
resistance or a low permeation to HS gas. Finish shall be corrosion resistant to
2
Hydrogen Sulfide; 20% Sulfuric Acid; 17% Nitric Acid; 5% Sodium Hydroxide; and up
to 6,000 mg/L chlorides.
For the Chesterton system, there shall be a minimum 6-inch overlap between the ARC
791 and S1HB coating systems.
2.3MIXING
Multiple-Component Coatings:
Prepare using each component as packaged by coating manufacturer. Mix only
components specified by coating manufacturer.
No partial batches will be permitted.
Do not use multiple-component coatings that have been mixed beyond their pot life.
Furnish small quantity kits for touchup coating and for coating other small areas.
Do not intermix additional components for reasons of color or otherwise, even within
the same generic type of coating.
Colorants: Formulate coatings with colorants free of lead, lead components, or other
materials that might be affected by presence of hydrogen sulfide or other gaslikely to be
present at Site.
2.4COLOR SCHEDULE
Colorof coating shall be manufacturer’s standard coating coloror gray.
EXECUTION
3.1GENERAL
ProvideRESIDENTPROJECT REPRESENTATIVEminimum seven days advance notice to start
of field surface preparation work and coating application work.
RESIDENT PROJECT REPRESENTATIVEshall observe surfaces prior to application of coatings
at each stage. Coatings which are applied on previous surface prior to observation are
subject to being stripped back to bare substrate and recoated.
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Work shall be performed with RESIDENT PROJECT REPRESENTATIVEaware of schedule,
unless prior approvalisgranted to perform work in RESIDENT PROJECT REPRESENTATIVE’S
absence.
3.2EXAMINATION
Observationby the RESIDENT PROJECT REPRESENTATIVEor OWNER does not limit the
CONTRACTOR’s responsibilities for quality control inspection and testing as specified herein
or as required by the Manufacturer's instructions.
Prior to commencement of work, thoroughly examine (and test as required)all conditions
and surfaces scheduled to be coated and report in writing to RESIDENT PROJECT
REPRESENTATIVEany conditions or surfaces that will adversely affect work. No work shall
commence until all such adverse conditions and defects have been corrected and surfaces
and conditions are acceptable.
Examine substrates and conditions, with Applicator present, for compliance with
requirements for maximum moisture content and other conditions affecting performance of
work.Moisture Content of Substratesshallbemeasured with an electronic moisture meter
and shall be as listed under Project Conditions paragraph above.
Concrete and Masonry Surfaces: Test for alkalinity prior to application of coating system.
Dampen surface area to be tested and apply pH indicator paper.
When a solvent base system is applied, pH shall be below 8.5.
If pH is above 8.5, apply an alkali resistant primer/sealer.
Verify suitability of substrates, including surface conditions and compatibility with existing
finishes and primers.
Begincoating application only after unsatisfactory conditions have been corrected and
surfaces are dry.The beginning of coating application constitutes CONTRACTOR'S
acceptance of substrates and conditions.
3.3PROTECTION OF ITEMS NOT TO BE COATED
Remove, mask, orotherwise protect plates, machined surfaces, hardware, threaded bolts,
couplings, shafts, bearings of stainless steel, aluminum,orfiberglass, and similar surfaces
already in place that are not to be coated. If removal is impractical or impossible because of
size or weight of item, provide surface-applied protection before surface preparation and
coating.
Mask openings in motors, vents, filters, etc. to prevent paint materials from entering.
After completing coating operations, use workers skilled in the trades involved to
reinstall items that were removed. Remove surface-applied protection if any.
Do not paint over labels of independent testing agencies or equipment name,
identification, performance rating, or nomenclature plates.
Cover pipe openings, floor openings andsumps during abrasive blasting to prevent
accumulation during surface preparation. Provide drop cloths to prevent coating materials
from falling on or marring adjacent surfaces.
Protect working parts of mechanical and electrical equipment from damage during surface
preparation and coating process.
Protect surfaces adjacent to or downwind of Work from overspray.
Remove empty coating containers from site and dispose of all excess materials and empty
containersin full accordance with all applicable state, federal, and local laws and
regulations.
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3.4SUBSTRATE SURFACE PREPARATION
Comply with manufacturer's written instructions and recommendations of paragraphs
specified below of Exterior and InteriorSurface Preparation Sections of “MPI Architectural
and Painting Specification Manual” applicable to substrates indicated.
Voids, bugholes, and other surface depressions shall be filled with manufacturer’s
underlayment or primer material.
Remove all surface contaminates such as form coatings, loose concrete, chemical salts, dust,
etc., by brush-blast cleaning as required; remove all grease,oils, and grime by washing with
an emulsifying alkaline base cleaner; follow with thorough rinsing in accordance with
manufacturer’s instructions. Comply with Section 09 91 00 “Painting and Protective
Coatings”for surface preparation in addition to the requirements of this specification.
Surface preparation procedures shall be in accordance with SSPC-SP13/NACE No. 6 and ICRI
Guideline No. 03732.Inspect the substrate in accordance with SSPC-SP13/NACE No. 6.
Test substrate for conductivity and ability to perform holiday testing prior to applying
coating.
3.5APPLICATION
Apply products in accordance with manufacturer's instructions in regard to drying time
between coats, technique of application, ventilation, paint thinning, and safety precautions.
Use applicators and techniques suited for coating and substrate.
Allow applied coat to dry for the time period specified by the coating manufacturer before
next coat is applied, but not longer than a “re-coat” window.
Apply each coat to uniform finish.
Where multiple coats are required; apply each coat with some method of indicating the
difference between coating layers.
Mask the line of demarcation between the coating systemand non-coated substrate to a
straight level line.
Concrete surfaces to be coated shall be coatedafter anchor bolts are installed, butprior to
installation of equipment, piping, conduit and supports and touched up following installation
of these items. Protect threaded bolts and anchors from coating the area.Components,
which cannot be adequately coated due to space limitations following installation, shall be
coated prior to installation and touched up after installation as well.
Film Thickness and Coverage:
Number of Coats:
Minimum required without regard to coating thickness.
Additional coats may be required to achieve minimum thickness.
Application Thickness:
Do not exceed coating manufacturer’s recommendations.
Measure using wet film thickness gauge to ensure proper coating thickness
during application.
Film Thickness Measurements and Electrical Inspection of Coated Surfaces:
Perform with properly calibrated instruments.
Where inspection shows that the specified thickness is not developed, apply
additional coats in accordance with manufacturer’s instructions and cure
schedule requirements toproduce the required dry film thickness.
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Attention shall be paid to edges, angles, flanges, and other similar areas, where
insufficient film thickness islikely to be present. Assure complete hiding of underlying
coats has been achieved.
Contractor shall terminate the coating on the edges of all areas to be coated per
Standard Detail 315.
3.6FIELD QUALITY CONTROL
CONTRACTOR shall be responsible for testing the conductivity of the concreteprior to
placing any coatings. The conductivity of the concrete should be checkedin multiple
locationsin each section separated by expansion joints.
CONTRACTOR shall be responsible for the following testing during coating operations:
Prior to start and during the coating application each day, temperature and humidity
readings will be obtainedafter concrete moisture and alkalinity are tested and found
in compliance. If the values obtained are not within the recommended temperature
and humidity range described herein or as required by the coating manufacture, the
coating application will not be allowed.Retain records of time mixed, volumes mixed,
coating times, recoat times and temperatures after completion for 24 hours.
Periodically check the wet film thickness during coating applications.
Submit records of the above tests and readingsto RESIDENT PROJECT
REPRESENTATIVE.
Testing Agency: CONTRACTORwill engagea qualified testing agency to perform tests and
inspections.
Minimum Dry Film Thickness (MDFT) readings will be obtained after final coathas
been applied. A test will be made for every 25 square feet of surface and at locations
designated by the RESIDENT PROJECT REPRESENTATIVE. A minimum of three
readings in eachlocation will be obtained. If the average of these readings indicates
the MDFTfor the final coat is below the specified minimum, CONTRACTOR shall apply
another coat in accordance with the manufacturer’s instructions.
The interiorsurfacesof liquid containing structures and tanks will be tested for
holidays after final coat application. Areas found to be defected shall have an
additional coat appliedas per manufactures recoat procedures.
Testing shall take place in the presence of the RESIDENT PROJECT
REPRESENTATIVE.
The coating system will be considered defective if it does not pass tests and inspections.
When this occurs the ENGINEER will specify corrective measures. The coating system will be
retested, with the additional expense occurred charged to the CONTRACTOR. Refer to
Division 1for additionalinformation regarding retesting and reinspection and “Execution
Requirements” for correction of work.
Testing of Coating Materials: Owner reserves the right to invoke the following procedure at
any time and as often as Owner deems necessary during the period when coatings are
being applied:
Owner will engage the services of a qualified testing agency to sample materials
being used. Samples of material delivered to Project site will be taken, identified,
sealed, and certified in presence of Contractor.
Testing agency will perform tests for compliance of coating materials with product
requirements.
Owner may direct Contractor to stop applying coatings if test results show materials
being used do not comply with product requirements. Contractor shall remove
noncomplying coating materials from Project site, pay for testing, and repaint
surfaces coated with rejected materials. Contractor will be required to remove
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rejected materials from previously coated surfaces if, on repainting with complying
materials, the two paints are incompatible.
Prepare test and inspection reports.
3.7CLEANING AND PROTECTION
At end of each workday, remove rubbish, empty cans, rags, and other discarded materials
from Project site.
After completing coating application, clean spattered surfaces. Remove spattered coating by
washing, scraping, or other methods. Do not scratch or damage adjacent finished surfaces.
Protect work of other trades against damage from coating application. Correct damage to
work of other trades by cleaning, repairing, replacing, and refinishing, as approved by
Architect, and leave in an undamaged condition.
At completion of construction activities of other trades, touch up and restore damaged or
defaced coated surfaces.
During progress of Work maintain premises free of unnecessary accumulationof tools,
equipment, surplus materials, and debris.
Collect waste, cloths, and material which may constitute a fire hazard, place in closed metal
containers and remove daily from site.
Upon completion of the work remove all staging and scaffolding. Dispose of all sand,
containers, and rubbish in a suitable manner. Remove overspray, coating spots, oil or stains
on adjacent surfaces. Leave the entire Project clean and acceptable.
END OF SECTION
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40 61 00 PROCESS CONTROL AND INSTRUMENTATION SYSTEMS - GENERAL PROVISIONS
1.00GENERAL
1.01SCOPE OF WORK
A.Process Control System Integrator (PCSI)
1.The General Contractor shall procure the services of a single PCSI to investigate, field
verify, select, furnish, configure, customize, debug, install all equipment, materials, and
labor and connect, calibrate, and place into operation all instrumentation and control
hardware and software, except for those services and materials specifically noted,
required to achieve a fully integrated and operational system as specified herein and in
other Specification sections listed below and as shown on the drawings.
2.Equipment furnished as a part of other Divisions, and shown on the Electrical Drawings
shall be integrated into the overall Process Instrumentation and Control System under
this Division. Instrumentation specified in other Divisions shall meet the Specification
requirements of this Division.
3.Provide Early Development System as specified in Section 1.01C herein.
4.The PCSI shall perform all Applications Systems Programming (ASP) work including:
a.PLC programming, testing of PLC logic, and start-up/training activities associated
with programmed portions of the PLC.
b.Connecting all the new PLCs to the existing Human Machine Interface (HMI) ,
Human Machine Interface (HMI) graphics development, database development, and
start-up/training activities associated with the configured portions of the HMI
system.
c.Historian programming to add historical data collection, trending, and calculations.
d.For the blower system programming work, PCSI/ASP to procure the services of a
pre-approved Blower ASP per the pre-negotiated fee and the scope of work. PCSI
shall collaborate with Blower ASP for the scope defined in the attachment A. PCSI is
responsible for providing all other services to achieve a fully integrated and
functional system as defined in the design documents.
5.The PCSI/ASP shall coordinate and schedule all required construction activities including
startup, testing, inspection and training with the General CONTRACTOR, OWNER, and
ENGINEER.
B.The work shall include furnishing, installing and testing the equipment and materials
detailed in the following sections:
Section Title
27 15 23 Fiber Optic Equipment
40 61 00 Process Control and Instrumentation Systems - General Provisions
40 61 00A Blower ASP Scope of Work
40 61 21 Process Control System – Testing
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Section Title
40 61 26 Process Control System – Training
40 61 93 Process Control System - Input Output List
40 61 93A Process Control System - Input Output List - Attachment A
40 61 96 Process Control Descriptions
40 61 96AProcess Control Descriptions – Attachment A – Aeration Blowers and Aeration Basins
40 61 96B Process Control Descriptions – Attachment B – Resaca Lift Station
40 63 00 PLC Hardware and Software
40 63 00A PLC Hardware and Software - Attachment A - PLC Hardware Schedule
40 66 00 Network Equipment
40 67 00 Control Panels and Components
40 68 00 Applications Engineering Services
40 68 00A Applications Engineering Services – Attachment A – Existing HMI Screens
40 70 00 Field Instruments
40 70 00A Field Instruments - Attachment A – Instrument Schedule
C.The work of this project includes, but is not necessarily limited to the following:
1.Provide instruments as indicated on the Drawings and specified herein.
2.Furnish and install new PLCs and associated modules as shown on the contract drawings
and specifications..
3.Provide PLC panel components as needed for complete functionality of the field
equipment and instrumentation systems associated with this project as indicated on the
drawings and specifications.
4.Furnish and install all communications network devices required per the Contract
Drawings
5.Provide fiber optic communications as indicated on the drawings and specifications.
6.Provide termination of field wiring, calibrations, and testing as specified herein.
7.Provide a new network panel inside the Resaca Electrical Building for the monitoring of
lift station signals from the plant HMI.
8.Provide demolitions according to the contract drawings. The existing
instruments/equipment that are being demolished shall be turned over to the Owner
during demolition work unless directed otherwise.
9.Any modifications to the existing control/network panels shall be marked up on the as-
built documentation and be included in the panel drawings submittal for approval.
10.Coordinate all PCSI work giving consideration to specified construction sequencing
constraints.
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11.Make connections, including field connections and interfacing between
instrumentation, controllers, control devices, control panels and instrumentation
furnished under other Divisions.
12.Auxiliary and accessory devices necessary for system operation or performance to
interface with existing equipment or equipment provided by other suppliers under
other Sections of these specifications shall be included whether or not they are shown
on the Drawings. These devices include but are not limited to, transducers, current
isolators, signal conditioners or interposing relays.
13.Equipment shall be fabricated, assembled, installed, and placed in proper operating
condition in full conformity with detail Drawings, Specifications, engineering data,
instructions, and recommendations by the equipment manufacturer as approved by the
ENGINEER.
14.Actual installation of the instrumentation system need not be performed by the PCSI's
employees; however, the PCSI, as a minimum, shall be responsible for the technical
supervision of the installation by providing on-site supervision to the installers of the
various components.
15.The PCSI shall furnish equipment which is the product of one manufacturer to the
maximum practical extent. Where this is not practical, all equipment of a given type
shall be the product of one manufacturer.
16.All materials, equipment, labor, and services necessary to achieve the monitoring and
control functions described herein shall be provided in a timely manner so that the
monitoring and control functions are available when the equipment is ready to be
placed into service.
17.Coordinate the sequence of demolition with the sequence of construction to maintain
operation.
18.All bidders shall become familiar with the project sites and scope, prior to submitting a
bid, and satisfy themselves as to any question that they might have, relating to existing
equipment, condition or construction. The PCSI shall plan for sufficient field time at the
site to confirm the design and existing system information provided with actual field
conditions for the purpose of work planning, panel design, programming,
documentation, and other work required to meet the project intent and functional
requirements.
19.Procurement and delivery of the Early Development System (EDS) shall be by the PCSI.
PCSI to deliver, unbox, and setup the EDS at the Blower ASP’s office location to facilitate
the testing of the Blower control scheme. Refer to testing requirements in Section 40 61
21, “Process Control System – Testing”. At minimum, following EDS hardware and
software are required (see the related design documents for the detailed
requirements):
a.Five Ethernet Network Switches
b.Five PLC processors, five power supplies, network accessories
c.Two OITs
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1.02RELATED WORK
A.General provisions of the Contract are included in Division 01 of the Specifications.
B.Specific control system and instrumentation materials and requirements are included in
related sections of Division 40.
C.Electrical equipment, conduit, cabling, and other requirements of the electrical contractor
are included in Division 26, Electrical Specifications.
D.Piping and Instrumentation Diagrams (P&ID) are included in the Drawings.
E.The SCADA System Architecture diagram is included in the Drawings.
1.03SUBMITTAL REQUIREMENTS
A.General
1.Refer to Division 01 for general submittal requirements.
2.Other Division 40 Sections may have additional submittal requirements.
3.Both electronic and hard submittals shall be bound separately in sections according to
the submittal list below, with an index page and section dividers. Electronic copies shall
be in Adobe PDF and/or AutoCAD format. Hard copy sets shall include five (5) sets of
reproducible, signed and sealed, full-size Drawings and five sets of Specifications. Hard
submittals shall be assembled in three-ring binders, up to 3 inches wide, with a
maximum of 11x17 (inch) size pages folded down to 8.5x11 (inch) size.
4.Shop drawing and manufacturer data sheet submittals shall be complete, an accurate
representation of equipment to be delivered, documented fully, and demonstrate that
equipment and services comply with Specification requirements.
5.PCSI/ASP Drawing submittals shall include a title block with, as a minimum, the
PCSI/ASP’s registered business name and address, PCSI/ASP project manager’s name,
OWNER and project name, Drawing title, sheet number, Drawing revision
number/description, and personnel responsible for the content of the Drawing.
6.Exceptions to the Specification and Drawing requirements shall be clearly identified and
defined by the PCSI/ASP and located within a separate section of each submittal.
Definitions of exceptions shall be presented for OWNER/ENGINEER approval and
include, at a minimum, Specification/Drawing reference location, description of
exception and proposed substitution, reason for exception, and details of any Contract
financial credits offered. Acceptance of “or Equal” substitutions and/or exceptions shall
be at the discretion of the OWNER/ENGINEER.
7.Partial, incomplete, or non-compliant submittals will be returned to the PCSI/ASP
without review.
8.Marked product literature of all equipment and features to be provided.
9.The CONTRACTOR shall check shop drawings for accuracy and compliance with the
requirements of the Contract Documents prior to submittal to the ENGINEER. Errors and
omissions on approved shop drawings shall not relieve the CONTRACTOR from the
responsibility of providing materials and workmanship required by the Specifications
and Drawings. Shop drawings shall be stamped with the date checked and a Statement
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indicating that the shop drawings conform to Specifications and Drawings. Only one
Specification Section submittal will be allowed per transmittal unless it has been
indicated that grouping is permitted in the individual sections.
10.Material shall not be ordered or shipped until the shop drawings or associated
submittals have been approved. No material shall be ordered or shop work started if
shop drawings or associated submittals are marked "FURNISH AS CORRECTED," "REVISE
AND RESUBMIT (RETURNED FOR CORRECTION)," or "REJECTED."
11.Separate submittals shall be supplied as listed below:
EDS Submittals
milestone after
Submittal Specification formal notice to
Item Submittal Title Number Number proceed
15 calendar
a.Project Plan 40 61 00-01 40 61 00 days
40 61 00 30 calendar
b.I/O List Submittal 40 61 00-02 40 61 93 days
90 calendar
c.Hardware and Software 40 61 00-03 40 61 00 days
120 calendar
40 61 00
days
d.Instrumentation 40 70 00-01 40 70 00
90 calendar
Network Devices and 40 61 00
days
e.Components 40 66 00-01 40 66 00
40 61 00 120 calendar
40 63 00 days
Control/Network Panel 40 66 00
f.Drawings 40 67 00-01 40 67 00
150 calendar
days
g.Fiber Optic System 27 15 23-01 27 15 23
40 68 00, 340 calendar
Applications System 40 61 93 days
h.Programming 40 68 00-* 40 61 96
360 calendar
days
i.PCSI Testing Plan 40 61 21-01 40 61 21, 40 68 00
300 calendar
days
j.PCSI Training Plan 40 61 26-01 40 61 26, 40 68 00
200 calendar
Spares, Expendables, and Test
days
k.Equipment 40 61 00-04 40 61 00
40 61 00 460 calendar
l.Final System Documentation 40 61 00-05 40 68 00 days
* Refer to indicated Specification Section or associated paragraph in this Section for details of submittal
requirements and quantities.
B.PCSI Project Plan Submittal
1.The PCSI Project Plan submittal shall be submitted prior to scheduling the PCSI/ASP
Kickoff Meeting. The OWNER/ENGINEER will not accept subsequent submittals until the
PCSI Project Plan submittal is approved.
2.The Project Plan submittal shall include, at a minimum:
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a.Overview of the proposed control system in clear text format describing the PCSI
understanding of the project work, preliminary system architecture drawing,
interfaces to other systems, schedule, startup, switchover, and coordination.
b.PCSI project schedule including meetings, milestones, submittals, procurement,
fabrication, shipment, installation, testing, commissioning, training, and other
related work tasks.
1).The project schedule shall be prepared using Microsoft Project scheduling
software in Gantt chart format, and shall clearly indicate task links and critical
path items.
2).PCSI schedule shall be based from and coordinated with the General
Contractor’s and ASP’s project schedule to meet all overall project milestones.
PCSI milestones shall include the following, as applicable to the project:
a).All subsequent project submittals shall be scheduled. Include in the time
allotment the time required for CONTRACTOR submittal preparation,
OWNER/ENGINEER's review time, and a minimum of two complete review
cycles.
b).Proposed dates for all project coordination meetings.
c).Hardware purchasing, fabrication, and assembly (following approval of
related submittals).
d).Software purchasing and configuration (following approval of related
submittals).
e).Shipment of all instrument and control system equipment.
f).Installation of all instrument and control system equipment.
g).Testing: Schedule for all testing. Testing schedule shall include submittal of
test procedures a minimum of 30 days prior to commencement of testing.
Schedule shall also include submittal of completed test procedure forms for
review and approval by the OWNER/ENGINEER prior to shipment, startup,
or subsequent project work.
h).Schedule for system cutover, startup, and/or going on-line for each major
system. At a minimum, include the schedule for each process controller and
HMI server/workstation provided or modified under this Contract.
i).Schedule for all training, including submittal and approval of O&M manuals,
factory training, and site training.
c.PCSI/ASP project organization chart including list of key personnel (project manager,
ENGINEER, lead technician, quality assurance reviewer, etc.); resumes; and written
commitment to this Project.
d.List of Exceptions to the Specifications and Drawings, based on a paragraph-by-
paragraph and Drawing-by-Drawing review of the Contract Documents and
Specifications. PCSI shall state their acceptance of all contractual Specification and
Drawing requirements outside of any Exceptions listed. If there is no statement by
the PCSI, then it is acknowledged that no exceptions are taken.
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C.I/O List Submittal
1.The PCSI generates a detailed I/O list using the I/O List template to be submitted to the
Engineer for review and approval.
a.Database Tag Name – PLC and HMI tag names shall be the same.
b.Database Tag Name Description.
c.PLC and HMI Address.
d.Engineer shall provide engineering ranges.
1).The ASP CANNOT progress in the PLC development process before receiving
official approval of this submittal.
2).Engineer shall verify naming convention conforms with PLC and HMI
Procedures.
3).The I/O List shall follow the I/O List format and be submitted as a Microsoft
Excel electronic document and 8-1/2 inch by 11-inch hard copy.
4).The I/O List shall include all active points and spare points for the system and
have a separate I/O List sheet for each PLC, RTU, or control panel system.
5).This process should not exceed three iterations to get approval.
6).The I/O list shall be arranged such that each control panel has a dedicated
worksheet. At a minimum, I/O worksheet tables shall include the following
information:
a).Tag name(s): The identifier assigned to a device that performs a function in
the control system. As part of this information, the loop number of the tag
shall be broken out to allow for sorting by loop.
b).Description: A description of the function of the device (text that includes
signal source, control function, etc.) Include the text “Spare Points” for all
I/O module points that are not connected to equipment.
c).Data Format.
d).Engineering Range/State: The range in engineering units corresponding to
an analog 4-20 mA signal, or the state at which the value of the discrete
points is “1.”
e).Engineering Units: The engineering units associated with the Analog I/O.
f).Alarm Limits: Include alarm limits based on the control descriptions and the
drawings.
g).Alarm State.
h).Alarm Priority: Include alarm priority based on OWNER’s preference.
i).HMI Update Rate.
j).Historical Logging.
k).Modbus Address: The Modbus address for peer-to-peer data points.
l).PLC Address.
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m).Wiring Information: The physical wiring termination points at the PLC
designated by rack, slot, and channel.
n).Signal Type: use DO - Discrete Output, DI - Discrete Input, AO - Analog
Output, AI - Analog Input, PI - Pulse Input, or PO – Pulse Output.
o).Instrument Limits.
p).State Text: Designation of the “on” and “off” state values for discrete points.
q).Output Type.
D.Hardware and Software Submittal
1.General
a.Submittals including only general sales literature will not be accepted.
b.Shop Drawing and manufacturer data sheet submittals shall be complete, fully
demonstrating compliance with all Specification requirements and features.
c.Selected features and options shall be clearly indicated by highlighting, circling, or
pointing arrows to each selection that makes up the manufacturer ordering/model
number code.
d.Physical details shall include, at a minimum, physical layout and dimensions,
construction details, NEMA rating, hazardous area rating, electrical power
requirements and consumption, communication ports, signal connection ports, heat
dissipation and installation requirements.
e.Functional details shall include, at a minimum, details of internal features such as
communication protocols, control functions, programming parameters, jumper
settings, software features, and licensing requirements.
2.Software
a.Provide a complete software list or Bill of Materials (BOM) including all software
items and quantities to be supplied by the PCSI.
b.Details of all stand-alone computer software packages required by the
Specifications.
c.System Software
1).Submit details of the process controller, local operator graphic panel, and HMI
software application packages to be used for each piece of equipment. All
standard and optional features to be provided shall be indicated.
d.Other Software
1).Submit details of all other required software packages to be provided, including
but not limited to network/communication utility (OPC, SNMP, UPS); field
instrument utility (HART, Fieldbus, etc.); and computer software (MS Office,
Adobe Acrobat, etc.).
e.Licensing
1).Provide details of all software license agreements indicating quantities and
assignment of licenses to the OWNER.
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f.Software Support
1).Provide details of all software support license agreements indicating quantities
and assignment of licenses to the OWNER.
3.Hardware
a.Provide a complete hardware list or Bill of Materials (BOM) including all hardware to
be supplied by the PCSI. For each hardware component indicated below, submit a
cover page that lists, at a minimum, date, specification number, product name,
manufacturer, model number, location(s), and power required. Preferred format for
the cover page is ISA S20, general data sheet; however, other formats will be
acceptable provided they contain all required information.
b.Catalog cuts for supplied Programmable Logic Controller (PLC), process controller
equipment, remote telemetry units (RTU), including central processing units,
redundancy units, memory, input modules, output modules, modems, network
interface modules, mounting racks, and power supplies. Submit descriptive
literature for each hardware component that fully describes the units being
provided.
c.Process Controller Memory Sizing Calculation
1).Submit calculations for controller program memory including additional
memory beyond the memory available for process control applications. This
includes scratch pad or "housekeeping" programs, additional overhead for
programming formats, redundancy, etc.; and shall be included in the total
memory sizing calculation. Submit calculations verifying that the total memory
provided will be adequate for the specified requirements.
d.Power Supply Sizing Calculations:
1).Submit calculations to show compliance with specified power supply sizing
requirements of the Specifications.
e.Battery Backup UPS Sizing and Runtime Calculations
1).Submit calculations to show compliance with specified UPS capacity sizing and
battery runtime requirements of the Specifications.
E.Instrumentation Submittal
1.The submittal shall include a complete instrument list or Bill of Materials (BOM)
including all instruments to be supplied by the PCSI. Instrument tagging shall adhere to
the loop numbering and tagging scheme shown within the Drawings and Specifications.
2.Submit complete documentation of each field instrument using an ISA-S20 style data
sheet format in electronic and 8.5x11 (inch) print format. Instrument data sheets shall
include the following information, at a minimum:
a.General (Header)
1).Instrument type (Title).
2).Specification reference.
3).Document revision number and date.
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b.Controller/Transmitter
1).Controller/Transmitter details shall include, at a minimum:
a).Physical: Size and dimensions of equipment. Materials of construction for
enclosure and wetted parts.
b).Ratings: NEMA rating, hazardous area classification and temperature ratings
for the equipment.
c).Sizing Calculations: Provide details of equipment selection based on any
manufacturer required sizing, calculations, configurations, etc.
d).Electrical Requirements: Note voltage, power requirements (two-wire or
four-wire) and power consumption data.
e).Inputs/Outputs: Input and output characteristics and types.
f).Heat Dissipation: Note manufacturer’s listed heat dissipation value for the
equipment.
g).Installation Details: Mounting details in sufficient detail to determine
compliance with the requirements of the Contract Documents.
h).Internal Features: Communication protocols, control functions,
programming parameters, jumper settings, software features, and licensing
requirements.
i).Range, size, and graduations in engineering units.
j).Complete manufacturer/model number.
c.Sensor
1).Sensor details shall include, at a minimum:
a).Physical: Size and dimensions of equipment. Materials of construction for
enclosure and wetted parts.
b).Ratings: NEMA rating, hazardous area classification and temperature ratings
for the equipment.
c).Sizing Calculations: Provide details of equipment selection based on any
manufacturer required sizing, calculations, configurations, etc.
d).Electrical Requirements: Note voltage, power requirements (two-wire or
four-wire) and power consumption data.
e).Inputs/Outputs: Input and output characteristics and types.
f).Installation Details: Mounting details in sufficient detail to determine
compliance with the requirements of the Contract Documents.
g).Internal Features: Communication protocols, control functions,
programming parameters, jumper settings, software features, and licensing
requirements.
h).Range, size, and graduations in engineering units.
i).Complete manufacturer/model number.
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d.Accessories and Special Requirements
1).List all required accessories, special options, software, tools and calibration
equipment to be provided. Provide complete manufacturer/model numbers for
each accessory and/or manufacturer option codes.
2).Submit details of digital network interface requirements including type, wiring
requirements, configuration details, device addressing, and process control
system interface.
3).Certified calibration data for all the analyzers.
e.Instrument Tag List
1).Provide specific project information for all instruments, of each type, included
on the ISA-S20 style data sheets. Instrument information shall include, at a
minimum:
2).Plant equipment number and tag number per the P&IDs, Owner tag naming
standards, and/or ENGINEER’s Instrument List.
3).Instrument description including plant area/system location.
4).Instrument scale range and engineering units (or setpoints for discrete
instruments).
5).Project drawing reference(s).
F.Control/Network Panel Drawings Submittal
1.Provide a complete list of all panels to be supplied by the PCSI.
2.Panel drawing submittals shall be complete, fully demonstrating compliance with all
specification requirements and features. Panel drawings shall include, but not be limited
to, the following for each panel supplied:
a.Panel Layout and Bill of Materials (with quantity)
b.Panel Power Wiring Schematics
c.Panel Input/Output Wiring Diagrams
3.Drawings shall be furnished for all panels, consoles, and equipment enclosures specified
in related sections. Panel assembly and elevation drawings shall be drawn to scale and
detail all equipment in or on the panel. Panel drawings shall be at least 11x17 (inch)
print size. As a minimum, the panel drawings shall include the following:
a.Interior and exterior panel elevation drawings to scale.
b.Nameplate schedule.
c.Conduit access locations.
d.Panel construction details.
e.Cabinet assembly and layout drawings to scale. The assembly drawing shall include
a bill of material on the drawing with each panel component clearly defined. The
bill of material shall be cross-referenced to the assembly drawing so that a non-
technical person can readily identify any component of the assembly by
manufacturer and model number.
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f.Fabrication and painting specifications including color (or color samples).
g.Panel control schematics and interconnection diagrams detailing the electrical
connections of all equipment in and on the panel. Diagrams shall include power and
signal connections, UPS and normal power sources, all panel ancillary equipment,
protective devices, wiring and wire numbers, and terminal blocks and numbering.
h.Point to point I/O wiring diagrams depicting wiring within the panel as well as
connections to external devices. The diagram shall identify all device terminal
points that the system connects to, including terminal points of equipment not
supplied by the PCSI, Wiring labeling used on the drawings shall match that shown
on the Contract Documents or as developed by the PCSI and approved by the
OWNER/ENGINEER. Field device wiring shall include the device ISA-tag and a unique
numeric identifier. PLC I/O wiring shall be numbered with rack number, slot
number, and point number. Two-wire and four-wire equipment shall be clearly
identified and power sources noted. Submit final wire numbering scheme for
approval by the OWNER/ENGINEER. Point-to-Point drawings shall be 11x17 (inch)
minimum in size.
i.Submit construction details, NEMA ratings, intrinsically safe barrier information, gas
sealing recommendations, purging system details, etc. for panels located in
hazardous locations or interfacing to equipment located in hazardous areas.
j.Heating and cooling calculations for each panel supplied indicating conformance
with cooling requirements of the supplied equipment and environmental
conditions. Calculations shall include the recommended type of equipment
required for both heating and cooling.
k.Submit evidence that all control panels shall be constructed in conformance with UL
508 and bear the UL seal confirming the construction. Specify if UL compliance and
seal application shall be accomplished at the fabrication location or by field
inspection by UL inspectors. All costs associated with obtaining the UL seal and any
inspections shall be borne by the CONTRACTOR and included in the Contract.
G.Testing Plan Submittal
1.PCSI Testing Plan shall incorporate Section 40 68 00, Process Control System -
Applications Engineering Services, for ASP testing requirements.
a.Refer to Section 40 61 96, Process Control System - Control Descriptions.
2.Test Procedure Submittals: Submit the procedures proposed to be followed for each
test. Procedures shall include test descriptions, forms, and checklists to be used to
control and document the required tests. Include sign-off forms for each testing phase
or loop with sign-off areas for the PCSI, ENGINEER, and OWNER. Refer to Division 40,
Section 40 61 21, Control System – Testing for specific testing requirements, and submit
separate procedures for each specified test phase.
3.Test Documentation: Upon completion of each required test, document the test by
submitting a copy of the signed-off test procedures. Testing shall not be considered
complete until the signed-off test procedures have been submitted and favorably
reviewed. Submittal of other test documentation, including "highlighted" wiring
diagrams with field technician notes, are not acceptable substitutes for the formal test
documentation.
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4.Each loop shall have a Loop Status sign-off form to organize and track its inspection,
adjustment, and calibration. These forms shall include the following information and
check-off items:
a.Project Name.
b.Loop Number.
c.Detailed test procedure indicating exactly how the loop will be tested including all
required test equipment, necessary terminal block numbers, and simulation
techniques required.
d.Tag Number for each component.
e.Check-offs/sign-offs for each component.
1).Tag/identification.
2).Installation.
3).Termination – wiring.
4).Termination – tubing.
5).Calibration/adjustment.
f.Check-offs/sign-offs for the loop.
1).Panel interface terminations.
2).I/O interface terminations.
3).I/O signal operation.
4).Inputs/outputs operational: received/sent, processed, adjusted.
5).Total loop operation.
6).Space for comments.
7).Sign-off and date fields for the CONTRACTOR, the OWNER/ENGINEER, and the
PCSI.
5.Each active analog subsystem element shall have a Component Calibration form. These
forms shall have the following information including space for data entry:
a.Project Name.
b.Loop Number.
c.ISA Tag Number and I/O Module Address.
d.Manufacturer.
e.Model Number/Serial Number.
f.Summary of Functional Requirements; for example:
1).For Indicators: Scale ranges.
2).For Transmitters/Converters: Scale and chart ranges.
3).For Computing Elements: Function.
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4).For Controllers: Action (direct/reverse) control modes (PID).
5).For Switching Elements: Unit range, differential (FIXED/ADJUSTABLE), reset
(AUTO/MANUAL).
6).For I/O Modules: Input or output.
g.Calibrations; for example:
1).For Analog Devices: Required and actual inputs and outputs at 0, 50, and 100
percent of span.
2).For Discrete Devices: Required and actual trip points and reset points.
3).For Controllers: Mode settings (PID).
4).For I/O Modules: Required and actual inputs or outputs for 0, 50, and 100
percent of span.
h.Space for comments.
i.Sign-off and date fields for the CONTRACTOR, the OWNER/ENGINEER, and the PCSI.
6.Inspection and Punch List Form
a.Testing forms shall include an inspection and punch list form to be filled out by
ENGINEER/OWNER.
H.Training Plan Submittal
1.PCSI Training Plan shall incorporate Section 40 68 00, Process Control System -
Applications Engineering Services.
a.Refer to Section 40 61 26, Process Control System – Training.
2.Training Plan Submittal
a.Upon receipt of the ENGINEER's comments on the preliminary training plan, submit
the specific proposed training plan. The training plan shall include:
1).Definitions, objectives, and target audience of each course.
2).Schedule of training courses including proposed dates, duration, and locations
of each class.
3).Complete copy of all proposed handouts and training materials. Training
information shall be bound and logically arranged with all materials reduced to
a maximum size 11x17 (inch), then folded to 8.5x11 (inch) for inclusion into the
binder.
I.Spares, Expendables, and Test Equipment Lists Submittal
1.This submittal shall include for each Subsystem:
a.A list of, and descriptive literature for, spares, expendables, and test equipment as
specified in Division 40.
b.A list of, and descriptive literature for, additional spares, expendables, and test
equipment recommended by the manufacturer.
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c.Unit and total costs for the additional spare items specified or recommended for
each subsystem.
J.Final System Documentation
1.Submit in accordance with Division 01 O&M requirements.
2.The Final System Documentation shall consist of operations and maintenance manuals
as specified herein. The manuals shall be bound in three-ring binders, maximum size of
3 inches, with drawings reduced to 11x17 (inch), then folded to 8.5x11 (inch) for
inclusion. Each section shall have a uniquely numbered tab divider, and each component
within each section shall have a separate binder tab divider.
3.The operations and maintenance manuals shall be prepared specifically for this
installation and shall include catalog data sheets, drawings, equipment lists,
descriptions, parts lists and operating and maintenance instructions, at a minimum,
contain the following information:
a.Table of Contents
1).A Table of Contents shall be provided for the entire manual with the specific
contents of each volume clearly listed. The complete Table of Contents shall
appear in each volume.
b.Instrument and Equipment Lists
1).The following lists shall be developed in Excel and provided not only as a hard
copy in O&M, but also electronically on a CD.
2).An instrument list for all devices supplied including tag number, description,
specification section and paragraph number, manufacturer, model number,
serial number, range, span, location, manufacturer phone number, local
supplier name, local supplier phone number, completion year replacement cost,
and any other pertinent data.
3).An equipment list for all non-instrument devices supplied listing description,
specification section and paragraph number, manufacturer, model number,
serial number, location, manufacturer phone number, local supplier name, local
supplier phone number, completion year replacement cost, and any other
pertinent data.
4).Submit Factory calibration result for the instruments. Each calibration /
recalibration certificates shall be signed and dated by a certified authorized
representative of the instrument manufacturer. PCSI shall furnish to
Owner/Engineer two copies of an installation inspection report certifying that all
equipment has been installed correctly and is operating properly. The report
shall itemize the equipment or shall have inspection reports for each item
attached to it. The report shall be signed by authorized representatives of both
the Contractor and the system supplier. As a minimum, the following
information shall be included in the Calibration Certificate:
a).Tag Number/Loop Number
b).Instrument Location
c).Manufacturer/Model Number
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d).Adjustable/Calibrated Range
e).Confirming that installation is per Manufacturer and per the contract
documents. If not, explain.
f).Calibration test (at 0%, 25%, 50%, 75%, and 100%)
g).Switch Test (at different setpoints)
h).Signature/date
c.Data Sheets with Vendor Operations and Maintenance Information
1).ISA S20 style data sheets shall be provided for all field instruments.
2).Cover page for each device, piece of equipment, and OEM software that lists, at
a minimum, date, specification number, product name, manufacturer, model
number, location(s), and power required. Preferred format for the cover page is
ISA S20, general data sheet; however, other formats will be acceptable provided
they contain all required information.
3).Final vendor O&M documentation for each device, piece of equipment, or OEM
software shall be either new documentation written specifically for this project,
or modified standard vendor documentation. All standard vendor
documentation furnished shall have all portions that apply clearly indicated with
arrows or circles. All portions that do not apply shall be neatly lined out or
crossed out. Groups of pages that do not apply at all to the specific model
supplied shall be removed.
4).For any component requiring dip switch settings or custom software
configuration, that information shall be included along with the corresponding
data sheets and O&M information.
5).Complete parts list with stock numbers, including spare parts.
d.Operations and Maintenance manuals shall be constructed in accordance with
Division 01 and shall include the following information:
1).Manufacturer’s contact address and telephone number for parts and service.
2).Instruction books and/or leaflets
3).Recommended renewal parts list
4).Record documents for the information required by the Submittals section
above.
e.Software Programs
1).Provide native backup files of the programming code for each new controller.
a).Programming code shall be fully annotated with comments describing the
functionality of each section and group of coding.
2).Provide native backup files of any modified PCS HMI software files.
f.Communication Equipment
1).Provide documentation and backup files for all communications programming
code, including all parameter settings.
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g.As-Built Drawings
1).Complete as-built drawings, including all drawings and diagram specified in this
section under the "Submittals" section. These drawings shall include all
termination points on all equipment the system in connected to, including
terminal points of equipment not supplied by the PCSI.
2).As-built documentation shall include information from submittals, as described
in this Specification, updated to reflect the as-built system. Any errors in or
modifications to the system resulting from the Factory and/or Functional
Acceptance Tests shall be incorporated in this documentation.
h.Original Licensed Software
1).Submit original software media of all software provided under this Contract.
Submit original paper based and electronic documentation for all software
provided. Submit license agreement information including serial numbers,
license agreements, User Registration Numbers and related information. All
software provided under this Contract shall be licensed to the OWNER at the
time of purchase. Provide media in software sleeves within O&M manual.
i.Electronic O&M Information
1).In addition to the hard copy of O&M data, provide an electronic version of all
equipment manuals on CD-ROM or DVD. Electronic documents shall be supplied
in Adobe Acrobat (PDF) format.
2).Provide electronic files for all custom-developed manuals. Text shall be supplied
in both Microsoft Office format and Adobe Acrobat format.
3).Provide electronic files for all drawings produced. Drawings shall be in AutoCAD
".dwg" format and in Adobe Acrobat format. Drawings shall be provided using
the AutoCAD eTransmit feature to bind external references, pen/line styles, and
fonts into individual zip files along with the drawing file.
4).Each computer system hardware device shall be backed up onto CD-ROM or
DVD after Substantial Completion and shall be turned over to the OWNER.
5).If specified in the training section, provide digital copies of all training videos.
Videos shall be in a format that is readable by standard DVD players and by
standard PC DVD drives. Format and shall be a minimum of 800 by 900 pixels
and shall include sound.
4.The cover and edge of each volume shall contain the following information:
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Project Name (refer to Contract Documents)
Contract Number (refer to Contract Documents)
Instrumentation and Control System
Hardware\[or Applications Engineering\] Operations and Maintenance Manual
Specification Sections _____, _____, ______
Subcontractor Name
Date
Volume X of Y
(Where X is the volume number and Y is the number of volumes)
1.04KICK-OFF/COORDINATION MEETINGS
A.Refer to Division 40, Section 40 68 00, Process Control System - Applications Engineering
Services for ASP work related meeting and workshop requirements.
B.PCSI/ASP Kick-off Meeting
1.A project kick-off coordination meeting shall be held within two weeks after submitting
the Project Plan and Schedule Submittal. The purpose of the meeting shall be:
a.To discuss the PCSI/ASP's Project Plan and Schedule Submittal.
b.To summarize the PCSI/ASP's understanding of the project.
c.Discuss any proposed substitutions or alternatives.
d.Schedule testing and delivery deadline dates.
e.Provide a forum to coordinate hardware and software related issues.
f.Request any additional information required from the OWNER.
2.Prepare and distribute an agenda for this meeting a minimum of one week before the
scheduled meeting date. The meeting will last up to two hours.
1.05REFERENCE STANDARDS
A.The equipment in this specification shall be designed and manufactured according to latest
revision of the following standards (unless otherwise noted):
1.National Electrical Safety Code (NESC).
2.Occupational Safety and Health Administration (OSHA).
3.American Petroleum Institute (API).
4.American Society for Testing and Materials (ASTM):
a.ASTM A269, Standard Specification for Seamless and Welded Austenitic Stainless-
Steel Tubing for General Service.
5.International Society of Automation (ISA).
6.Insulated Cable Engineers Association (ICEA).
7.National Electrical Manufacturers Association (NEMA).
8.National Fire Protection Agency (NFPA):
a.NFPA 70E, National Electrical Code (NEC).
b.NFPA 79, Electrical Standard for Industrial Machinery.
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9.Underwriters Laboratories, Inc. (UL):
a.UL 508, the Standard of Safety for Industrial Control Equipment.
b.UL 508A, the Standard of Safety for Industrial Control Panels.
c.UL 50, the Standard of Safety for Enclosures for Electrical Equipment.
10.Factory Mutual (FM).
11.American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)
handbooks and standards.
12.Sheet Metal and Air Conditioning Contractors National Association (SMACNA) standards.
13.American Society of Plumbing Engineers (ASPE) design guides.
14.Texas Commission on Environmental Quality (TCEQ).
15.American Water Works Association (AWWA).
16.All equipment and installations shall satisfy applicable Federal, State, and local codes.
17.All meters, relays and associated equipment shall comply with the requirements of the
National Electric Code and Underwriters Laboratories (UL) where applicable.
18.Each specified device shall also conform to the standards and codes listed in the
individual device paragraphs.
B.Where reference is made to one of the above standards, the revision in effect at the time of
bid opening shall apply.
1.All material and equipment, for which a UL standard exists, shall bear a UL label. No
such material or equipment shall be brought onsite without the UL label affixed.
2.If the issue of priority is due to a conflict or discrepancy between the provisions of the
Contract Documents and any referenced standard, or code of any technical society,
organization, or association, the provisions of the Contract Documents shall take
precedence if they are more stringent or presumptively cause a higher level of
performance. If there is any conflict or discrepancy between standard specifications, or
codes of any technical society, organization or association, or between Laws and
Regulations, the higher performance requirement shall be binding on the CONTRACTOR,
unless otherwise directed by the OWNER/ENGINEER.
3. In accordance with the intent of the Contract Documents, the CONTRACTOR accepts
the fact that compliance with the priority order specified shall not justify an increase in
Contract Price or an extension in Contract Time, nor limit in any way the CONTRACTOR's
responsibility to comply with all Laws and Regulations at all times.
4.All control panels shall be constructed and the labeling shall be affixed in a UL 508
facility.
1.06QUALITY ASSURANCE
A.The Process Control System Integrator (PCSI) shall be a "systems integrator" regularly
engaged in the design and the installation of instrumentation systems and their associated
subsystems as they are applied to the municipal water and wastewater industry. For the
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purposes of this Specification Section, a "systems integrator" shall be interpreted to mean
an organization that complies with all of the following criteria:
1.Employs personnel on this project who have successfully completed ISA or
manufacturer’s training courses on general process instrumentation and configuration
and implementation of the specific programmable controllers, computers, and software
proposed for this project. Key personnel shall hold ISA CCST Level 1 certification or have
a minimum of 10 years of verifiable plant start-up experience. Key personnel shall
include, as a minimum, the lead field technician. Key personnel shall have experience
with the Studio 5000, and Rockwell Automation/Allen Bradley ControlLogix and
CompactLogix family of PLC.
2.Employs a registered professional Control Systems Engineer or Electrical Engineer in the
state of Texas to supervise or perform the work required by this Specification Section.
3.Has successfully completed work of similar or greater complexity on at least three
previous projects within the last five years. Successful completion shall be defined as a
finished project completed on time, without any outstanding claims or litigation
involving the PCSI. Potential references shall be for projects where the PCSI's contract
was of similar size to this Project.
4.Has been in the water/wastewater industry performing the type of work specified in this
specification section for a minimum of five continuous years.
5.Maintain adequate appropriate insurance as required as determined by the Owner’s
representative.
6.Be an authorized Allen-Bradley/Rockwell Systems Integrator Contractor, Solutions
Provider.
7.Employ a PMI or PMP certified project manager.
B.The PCSI shall maintain a permanent, fully staffed and equipped service facility within 200
miles of the project site with full-time employees capable of designing, fabricating,
configuring, installing, calibrating, and testing the systems specified herein. At a minimum,
the PCSI shall be capable of responding to on-site problems within 12 hours of notice.
Provide an on-site response within four hours of notification starting at two months before
scheduled start-up to two months after start-up completion.
C.PCSI shall hold a valid UL 508 certification for their panel fabrication facility.
D.The following PCSI and ASP Contractors, listed in no particular order, have been pre-
approved for this work:
1.Prime Controls
Contact: Brian Poarch
Address: 1725 Lakepointe Dr., Lewisville, Texas 75057
Phone: (972) 221-4849
2.Control Panels USA, Inc.
Contact: Brian Wetherholt
Address: 16310 Bratton Lane, Suite 100, Austin, Texas 78728
Phone: (512) 863-3224
3.Richardson Logic Controls
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Contact: David Smith
Address: 8115 Hicks Hallow, McKinney, Texas 75071
Phone: (972) 542-7375
4.TESCO Controls, Inc.
Contact: Brian Adams
Address: 8000 Jetstar Rd., Suite 150, Irving, Texas 75063
Phone: (817) 343-7163
E.The following Blower ASP Contractor(s), listed in no particular order, have been pre-
approved for this work:
1.Atlas Copco Compressors, LLC (only for Blower building PLC programming)
Contact: Gatlin Gold
Address: 15045 Lee Rd Houston, Texas 77032
Phone: (832) 297-7916
F.Being listed in this specification does not relieve any potential PCSI or Blower ASP from
meeting the qualifications specified in this Section.
G.Only approved suppliers will be accepted. The Contractor must name the proposed
PCSI/ASP and Blower ASP.
1.07DELIVERY, STORAGE, AND HANDLING
A.Delivery, storage, and handling shall be in accordance with Division 01, General
Requirements.
B.Equipment shall be installed in its permanent, finished location shown on the Drawings
within seven calendar days of arriving onsite. If the equipment cannot be installed within
seven calendar days, the equipment shall not be delivered to the site, but stored offsite, at
the CONTRACTOR’s expense, until such time that the site is ready for permanent installation
of the equipment.
C.Shipping Precautions
1.After completion of shop assembly, factory test, and approval of all equipment,
cabinets, panels, and consoles shall be packed in protective crates and enclosed in
heavy duty (5 mil) polyethylene envelopes or secured sheeting to provide protection
from damage, dust, and moisture. Dehumidifiers shall be placed inside the polyethylene
coverings. The equipment shall then be skid-mounted for final transport. Lifting rings
shall be provided for moving without removing protective covering. Boxed weights shall
be shown on shipping tags together with instructions for unloading, transporting,
storing, and handling at the job Site.
2.Manufacturer's special instructions for field handling, storage, and installation required
for protection shall be securely attached to the packaging for each piece of equipment
prior to shipment. The instructions shall be stored in resealable plastic bags or other
means of protection. Two copies of these instructions shall be included with the
equipment at time of shipment, and shall be made available to the CONTRACTOR and
OWNER.
3.If any apparatus has been damaged, such damage shall be repaired at no additional cost
to the OWNER.
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1.08NOMENCLATURE AND IDENTIFICATION
A.Field Instrument Tags
1.A permanent stainless steel tag firmly attached and permanently and indelibly marked
with the following, as indicated in the drawings, and provided on each piece of
equipment supplied under this Section. Equipment shall be tagged before shipping to
the Site.
a.Instrument tag number.
b.Manufacturer Name.
c.Model Number.
d.Serial Number.
2.Provide 1/8-inch by 3/8-inch, Type 316 stainless steel button head, self-tapping machine
screws.
3.All supplied field instrument transmitters and field instrument transmitter elements
shall have a stainless steel identification tag attached to each transmitter and element
prior to shipment. Tag shall be attached via stainless steel chain or stainless steel wire
(24 gauge minimum) to a non-removable part of the device. The tag size shall be a
minimum of 3x2 inch ratio. Tag shall include the ISA alphanumeric instrument number
as indicated in the P&ID, loop, and detail drawings. The alphanumeric instrument
number shall be stamped into the tag and shall have a minimum of 3/16-inch-high
alphanumeric characters.
B.Panel/Enclosure Nameplates
1.Nameplates shall be engraved, laminated impact acrylic, black lettering on a white
background, matte finish, not less than 1/16-inch thick by 3/4-inch by 2-1/2-inch,
Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures, except
for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with
double faced adhesive strips, TESA TUFF TAPE 4970, .009 X ½-inch. Prior to installing the
nameplates, the metal surface shall be thoroughly cleaned with a 70% alcohol solution
until the metal surface residue has been removed. Epoxy adhesive or foam tape is not
acceptable.
2.See Instrumentation and Controls – Control Panels and Equipment Section.
1.09WARRANTY
A.Provide warranty per Division 01, Warranties and Bonds, and as specified herein.
B.The Manufacturer shall warrant the equipment to be free from defects in material and
workmanship for two years from the date of acceptance of the equipment containing the
items specified in this Section. Within such period of warranty the Manufacturer shall
promptly furnish all material and labor necessary to return the equipment to new operating
condition. Any warranty work requiring shipping or transporting of the equipment shall be
performed by the CONTRACTOR at no expense to the OWNER.
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1.10PROJECT/SITE REQUIREMENTS
A.Environmental Requirements. Refer to Division 26, Electrical and the Electrical drawings for
specific environmental and hazardous area classifications.
B.Elevation: Equipment shall be designed to operate at the project ground elevation.
C.Temperature
1.Equipment located in outdoor areas shall operate between \[- 5 to 50 C\] degrees
ambient minimum.
2.Equipment located in indoor areas shall operate between \[10 to 35 C\] degrees ambient
minimum.
3.Storage temperatures shall range from \[0 to 50 C\] degrees ambient minimum.
4.Additional cooling or heating shall be furnished if required by the equipment as
specified herein.
D.Relative Humidity
1.Air-conditioned area equipment shall operate between \[20 to 95\] percent relative, non-
condensing humidity. All other equipment shall operate between 45 to 100 percent
relative, condensing humidity.
2.00PRODUCTS
2.01GENERAL REQUIREMENTS
A.Auxiliary components necessary for full system operation shall be provided whether they
are shown on the Drawings or not. These components include but are not limited to
transducers, relays, signal amplifiers, and signal isolators required for interface with existing
equipment and/or equipment provided by others within other specification sections of this
Contract. The PCSI shall be responsible for coordinating mechanical and electrical interface
requirements to the Control System.
B.Equipment fabrication, assembly, procurement, and installation shall fully conform to
project specifications, drawings, details, engineering data, instructions, and manufacturer
requirements. Substitutions to specified equipment or functionality must be specifically
noted and approved by the OWNER/ENGINEER prior to implementation. To the furthest
extent possible and to accommodate future operation and maintenance, equipment of
similar type shall be from the same manufacturer and match the OWNER’s existing install
base (unless specifically noted otherwise).
C.All equipment and installations shall comply with applicable Federal, State, and local codes.
D.Equipment, instrument, and loop numbering schemes and PLC I/O addressing shall be
coordinated and approved by City of Corpus Christi. Deviation or modification of numbering
schemes will not be acceptable unless approved by the OWNER/ENGINEER.
E.The PCSI shall, at the time of purchasing, review equipment with the OWNER/ENGINEER,
manufacturers, and vendors to ensure the latest hardware and software versions are
purchased.
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F.All instrumentation and electronic equipment shall be of the manufacturer's latest design,
utilizing printed circuitry and epoxy or equal coating to prevent contamination by dust,
moisture, and fungus. The field-mounted equipment and system components shall be
designed for installation in dusty, humid, and slightly corrosive service conditions.
G.All equipment, cabinets, and devices furnished shall be heavy-duty type, designed for
continuous industrial service. The system shall contain similar products of a single
manufacturer, and shall consist of equipment models which are currently in production. All
equipment provided shall be of modular construction and shall be capable of field
expansion.
H.All electronic/digital equipment shall be provided with radio frequency interference
protection.
I.Equipment shall be the manufacturer’s latest and proven design at no extra cost to the
Owner. In the event of a compatibility issue, Contractor furnished equipment may match
current configuration of equipment and software currently in use by the Owner, if approved
by the Owners Representative.
J.The Specifications and Drawings call attention to certain features, but do not purport to
cover all details entering into the design of the instrumentation system. The completed
system shall be compatible with the functions required and the equipment furnished by the
Contractor.
K.Ground paired shielded at the PLC end only and insulate from ground elsewhere. The shield
shall be continuous for the entire run. The paired shielded cable shall not be laced with or
placed in the same conduit with power cables. The shield of shielded cable shall only be
broken when the conductors are terminated on terminal strips.
L.Ground conductors shall be bare tinned copper where directly buried and insulated in all
other cases.
2.02GENERAL REQUIREMENTS – INSTRUMENTATION
A.All instruments shall be provided with mounting hardware and floor stands, wall brackets,
or instrument racks unless otherwise noted. Fasteners for securing control panels and
enclosures to walls and floors shall be either hot-dipped galvanized after fabrication or
stainless steel. Provide stainless steel fasteners only in corrosive areas rated NEMA 4X on
the drawings or as defined under Division 26, Electrical. Provide and size anchors in
accordance with Divisions 01 and 05 as required per the seismic calculations. Provide
minimum size anchor of 3/8-inch.
B.All indicators shall be linear in process units, unless otherwise noted. All transmitters shall
be provided with indicators in process units, accurate to 2 percent or better.
C.Two-wire transmitter located in a facility area classified as hazardous per the NFPA and the
NEC shall be made safe by means of an intrinsic safety barrier.
D.Four-wire transmitters shall be isolated from the process and power or provided with a
loop-powered signal current isolator connected to the output signal circuit.
E.Transmitters/instruments shall be provided with HART communications.
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2.03GENERAL REQUIREMENTS – ELECTRICAL
A.Equipment shall operate on a 60 Hertz alternating current power source at a nominal 120
volts, plus or minus 10 percent, except where specifically noted. Regulators and power
supplies required for compliance with the above shall be provided between power supply
and interconnected instrument loop. Where equipment requires voltage regulation,
constant voltage transformers shall be supplied.
B.With the exception for field device network connected devices, all electronic
instrumentation shall utilize linear transmission signals of isolated 4 to 20 mA DC
(milliampere direct current) capable of driving a load up to 750 Ohms, unless specified
otherwise. However, signals between instruments within the same panel or cabinet may be
1-5 VDC (volts direct current).
C.Outputs of equipment that are not of the standard signals as outlined shall have the output
immediately raised and/or converted to compatible standard signals for remote
transmission. No zero-based signals will be allowed.
D.All switches shall have double-pole double-throw contacts rated at a minimum of 900 VA,
unless noted otherwise.
E.Switches and/or signals indicating an alarm, failure, or upset condition shall be wired fail-
safe to the SCADA system. A fail-safe condition is an open circuit when in an alarm state.
F.Materials and equipment shall be UL approved. Where components are not available with
UL approval, integrate the device with ground fault protective devices, isolation
transformers, fuses, or other protective equipment necessary to achieve compliance with UL
508 requirements.
G.All equipment furnished shall be designed and constructed so that in the event of power
interruption, the systems specified herein shall go through an orderly shutdown with no loss
of memory and shall resume normal operation without manual resetting when power is
restored, unless otherwise noted.
H.All transmitter output signals shall include signal and power source isolation.
I.Provide local electrical shutoffs and disconnects for all four-wire field instruments requiring
120 VAC power. Electrical disconnects shall be suitably rated disconnect switches or manual
motor starters as specified under Division 26, Electrical.
2.04LIGHTNING AND SURGE PROTECTION DEVICES
A.General - Surge protection shall be provided to protect the electronic instrumentation
system from induced surges propagating along the signal and power supply lines from
lightning, utility, or the plant electrical system. The protection systems shall be such that the
protective level shall not interfere with normal operation, but shall be lower than the
instrument surge withstand level. Protection shall be maintenance-free and self-restoring.
Devices shall have a response time of less than 50 nanoseconds and be capable of handling
a discharge surge current (at an 8x20µs impulse waveform) of at least 8 kA. Ground wires
for all instrumentation device surge protectors shall be connected to a low resistance
ground in accordance with Division 26, Electrical.
B.Provide protection of all analog signal (4-20 mA) circuits where any part of the circuit is
outside of the building envelope. Circuits shall be protected at both the transmitter and the
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control system end of the circuit. Protection devices located near the transmitter shall be
mounted in a separate enclosure, unless conduit mounted; and shall be Phoenix Contact PT
Series, or approved equal. Substitution of a single device to protect both 120 VAC and 4-20
mA wires to an instrument is acceptable. Protection devices in control panels shall be MTL
Surge Technologies (Telematic) SD Series, Phoenix Contact PT Series, Citel BP1-24, or equal.
C.Provide protection of all 120 VAC power feeds into control panels, instruments, and control
room equipment. Surge arresters shall be Transtector ACP-100BW Series, Phoenix Contact
"Mains-PlugTrab", MCG Surge Protection 400 Series, or equal.
1.Provide protection of all 120 VAC power feeds into network panels. Surge arresters shall
be Transtector SP50-1201P.
D.Non-Fiber Based Data Highway or Communications Circuits – Provide protection on all
communication and data highway circuits that leave a building or are routed external to a
building. Circuit protection shall be provided at both ends of the line. Surge protection
devices shall be Phoenix Contact PlugTrab Series, Transtector FSP Series, MTL Surge
Technologies (Telematic) NP Series, or equal.
E.Inductive Loads – At a minimum, provide coil surge suppression devices, such as varistors or
interposing relays, on all process controller outputs or switches rated 120 VA or less that
drive solenoid, coil, or motor loads.
F.Telephone Circuits – At a minimum, provide Telephone Company approved line protection
units for all telephone lines used for telemetry or SCADA system use under this Contract.
2.05TUBING AND FITTINGS
A.All instrument air header takeoffs and branch connections less than 2 inch shall be 316
stainless steel.
B.All instrument shut-off valves and associated fittings shall be supplied in accordance with
the piping specifications and all instrument installation details. The materials for fittings and
valves shall be compatible with process fluids. Where metallic fittings and valves are
compatible, wetted materials shall be Type 316 stainless steel.
C.The materials for instrument tubing shall be compatible with process fluids. Where metallic
tubing is compatible, tubing shall be fully annealed ASTM A269 Seamless 316 grade free of
OD scratches having the following dimensional characteristics as required to fit the specific
installation:
1.1/4-inch to 1/2-inch O.D. by 0.035-inch wall thickness.
2.5/8-inch to 1-inch O.D. by 0.049-inch wall thickness.
3.1-inch O.D. by 0.065-inch wall thickness.
4.1-1/4-inch O.D. by 0.065-inch wall thickness.
5.1-1/2-inch O.D. by 0.083-inch wall thickness.
6.2-inch O.D. by 0.095-inch wall thickness.
D.All process connections to instruments shall be annealed 1/2-inch O.D. stainless steel
tubing, Type 316.
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E.All tube tracks shall be supported by stainless steel and installed as per manufacturer's
installation instructions.
2.06SPARE PARTS
A.Spare parts of the type and quantity as recommended by the manufacturer shall be
furnished for all devices furnished under these sections.
B.All spare parts shall be wrapped in bubble wrap, sealed in a polyethylene bag complete with
dehumidifier, then packed in cartons and labeled with indelible markings. Complete
ordering information including manufacturer's part number, part ordering information
including manufacturer, part number, part name, and equipment name and number(s) for
which the part is to be used shall be supplied with the required spare parts. The spare parts
shall be delivered and stored in a location directed by the OWNER/ENGINEER.
C.As a minimum, furnish the following spare parts for control panels:
1.One-half dozen replacement fuses, all types and sizes.
D.The following Spare Parts shall be furnished and utilized as the Application Development
System. At the completion of the project the Application Development system shall be
turned over to the Owner as spare parts.
1.PLC Rack
a.One Power Supply.
b.One CPU of the largest memory size model provided.
c.One IO Module of each type.
2.07TEST EQUIPMENT
A.Provide all test equipment, instruction manuals, carrying/storage cases, unit battery
charger, special tools, calibration fixtures, cord extenders, patch cords, test leads, and
miscellaneous items for checking field operation of all supplied equipment.
B.All test equipment shall be wrapped in bubble wrap, sealed in a polyethylene bag with a
dehumidifier, then packed in cartons and labeled with indelible markings. Complete
ordering information including manufacturer's part number and equipment name shall be
supplied. The test equipment shall be delivered and stored in a location directed by the
OWNER/ENGINEER.
3.00EXECUTION
3.01GENERAL REQUIREMENTS – INSTALLATION
A.All equipment and installations shall satisfy applicable Federal, State, and local codes.
B.Instrumentation and accessory equipment shall be installed in accordance with the
manufacturer's instructions. The locations of equipment, transmitters, alarms, and similar
devices indicated are approximate only. Exact locations of all devices shall be as approved
by the OWNER/ENGINEER during construction. Obtain in the field all information relevant to
the placing of process control equipment and, in case of any interference with other work,
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proceed as directed by the CONTRACTOR and furnish all labor and materials necessary to
complete the work in an approved manner at no additional cost to the OWNER.
C.All equipment used in areas designated as hazardous shall be designed for the Class, Group
and Division as required for the locations as shown on the Drawings and specified in Division
26, Electrical. All work shall be in strict accordance with codes and local rulings.
D.Unless specifically indicated, direct reading or electrical transmitting instrumentation shall
not be mounted on process piping. Instrumentation shall be mounted on instrument racks
or stands. All instrumentation connections shall be provided with shut-off and drain valves.
For differential pressure transmitters, five-valve manifolds for calibration, testing, and blow
down service shall also be provided. For chemical or corrosive fluids, diaphragm seals with
flushing connections shall be provided.
E.All piping and tubing to and from field instrumentation shall be provided with necessary
unions, calibrations and test tees, couplings, adaptors, and shut-off valves. Process tubing
shall be installed to slope from the instrument toward process for gas measurement service
and from the process toward the instrument for liquid measurement service. Provide
drain/vent valves or fittings at any process tubing points where the required slopes cannot
be maintained. Process tubing shall be installed rigidly with supports to prevent significant
vibrations.
F.Brackets and hangers required for mounting of equipment shall be provided. They shall be
installed as shown and not interfere with any other equipment.
G.The shield on each process instrumentation cable shall be continuous from source to
destination and be grounded at only one ground point for each shield.
H.Investigate each space in the building through which equipment must pass to reach its final
location. If necessary, ship material in sections sized to permit passing through restricted
areas in the building. Provide on-site service to oversee the installation, the placing and
location of system components, their connections to the process equipment panels,
cabinets and devices, subject to the ENGINEER's approval. Certify that field wiring
associated with his/her equipment is installed in accordance with best industry practice.
Schedule and coordinate work under this section with that of the electrical work specified
under applicable Sections of Division 26, Electrical.
I.Installation of fiber optic cable within control panel and console assemblies. Refer to cable
manufacturer's specifications for bend radius. Use cable breakout assembly as
recommended by the cable manufacturer. Provide wire basket, strain relief as required to
meet manufacturer's strain requirements.
J.Provide local electrical shutoffs and disconnects for all four-wire field instruments requiring
120 VAC power. Electrical disconnects shall be suitably rated disconnect switches or manual
motor starters as specified under Division 26, Electrical.
K.Provide sunshades for equipment mounted outdoors in direct sunlight. Sunshades shall
include standoffs to allow air circulation around the cabinet. Sunshields shall be sized to
allow a minimum or 6” clearance on each side of instrument or transmitter. Sunshield shall
be equipped with glare shield with continuous hinge spot welded to sunshield to protect the
transmitter display. Orient equipment outdoors to face to the North or as required to
minimize the impact of glare on LED, LCD, or other digital readouts.
L.Loop Tuning
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1.All electronic control stations incorporating PID controllers shall be tuned following field
installation and calibration of instrumentation and control system components, but
prior to commencement of the specified field tests. Field testing will be immediately
‘failed’ if loop tuning for the entire installed system is not complete.
2.Optimal loop tuning shall be achieved either by auto-tuning software or manually by
trial and error, Ziegler-Nichols step-response method, or other documented process
tuning method. Assigning common PID factors for identical loops following field tuning
of a single typical loop is acceptable. However, the Final Documentation Manuals shall
include the loop tuning configuration parameters for each loop individually as specified
in PART 1 of this section.
M.Determine and configure optimal tuning parameters to assure stable, steady state operation
of final control elements running under the control of field-mounted, dedicated PID
controllers or software-based PID controllers residing as part of the programmable logic
controller system. Each control loop that includes anti-reset wind-up features shall be
adjusted to provide optimum response following start-up from an integral action saturation
condition.
N.Tune all PID control loops to eliminate excessive oscillating final control elements. Loop
parameters shall be adjusted to achieve 1/4 amplitude damping or better. In addition, loop
steady state shall be achieved at least as fast as the loop response time associated with
critical damping.
O.Loop performance and stability shall be verified in the field following tuning by step changes
to setpoint. Submit loop tuning methodology and verification as part of the final system
documentation as specified in Part 01.
P.For cascade loops, tune both sets of controllers so that the cascade loop achieves the loop
tuning characteristics specified herein.
Q.Instrument Mounting:
1.Mount all instruments where they will be accessible from fixed ladders, platforms, or
grade.
2.Mount all local indicating instruments with face toward the normal operating area,
within reading distance, and in the line of sight, free from interference with piping,
conduit and equipment.
3.Mount to provide:
a.Protection from heat, shock, and vibrations.
b.Provide accessibility for maintenance.
3.02GENERAL REQUIREMENTS – TESTING
A.Refer to Division 40 Section 40 61 21, Process Control System – Testing.
3.03GENERAL REQUIREMENTS – TRAINING
A.Refer to Division 40 Section 40 61 26, Process Control System – Training.
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ATTACHMENTS
40 61 00A Attachment A - Blower ASP Scope of Work
END OF SECTION
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40 61 21 PROCESS CONTROL SYSTEM - TESTING
1.00PRODUCTS
1.01SCOPE OF WORK
A.The Process Control System Integrator (PCSI) shall provide all testing, testing procedures,
testing forms, and testing coordination with the OWNER/ENGINEER specified herein and
within Division 40 Section, Process Control and Instrumentation Systems – General
Provisions.
B.The Process Control Systems Integrator (PCSI) shall supervise and/or perform the
requirements of this Section. As part of these services, the PCSI shall include, for those
equipment items not manufactured by him, the services of an authorized manufacturer's
representative to check the equipment installation and place that portion of the equipment
in operation. The manufacturer's representative shall be thoroughly knowledgeable about
the installation, operation, and maintenance of the manufacturer’s equipment.
C.The CONTRACTOR shall provide all test equipment and staff necessary to perform the
testing as specified herein.
D.All Process Instrumentation and Control System hardware and software shall be thoroughly
tested to verify proper operation as an integrated system.
E.Any defects or problems found during the testing activities shall be corrected by the
CONTRACTOR and then retested to demonstrate proper operation.
F.Check and confirm the proper installation of all instrumentation and control components
and all cable and wiring connections between the various system components prior to
placing the various processes and equipment into operation.
G.Conduct a complete system checkout and adjustment, tuning of control loops, checking
operation functions, and testing of final control actions. All problems encountered shall be
promptly corrected to prevent any delays in startup of the various unit processes.
H.The PCSI shall be responsible for initial operation of the Process Instrumentation and
Control System and shall make any required changes, adjustment or replacements for
operation, monitoring, and control of the various processes and equipment necessary to
perform the functions intended.
I.All spare parts must be on site and accepted prior to commencement of field testing.
J.The CONTRACTOR shall provide the following documentation for use during the testing
activities.
1.Complete panel schematic and internal point-to-point wiring interconnect Drawings.
2.Complete electrical control schematics in accordance with JIC standards.
3.Complete panel layout Drawings.
4.Complete field wiring diagrams.
5.Complete instrument loop diagrams.
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6.Completed Calibration/Recalibration Certificates for all field and panel devices that
require adjustment or calibration.
K.CONTRACTOR shall provide one set of the above-listed documentation for the OWNER's
personnel, one set for the ENGINEER’s use, one set for field use, and the required number
of sets for the CONTRACTOR’s use.
L.The Drawings corrected and modified during testing shall form the basis for the "As-Built"
Record Drawing requirement.
M.CONTRACTOR shall furnish to ENGINEER two copies of an installation inspection report
certifying that all equipment has been installed correctly and is operating properly. The
report shall be signed by authorized representatives of both CONTRACTOR and the system
supplier.
N.The Operator Interface Terminals (OITs) screens shall be tested when they are being
replaced or modified under this project.
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
B.Refer to Division 40, Section 40 68 00, Applications Engineering Services.
1.03SUBMITTAL REQUIREMENTS
A.Refer to Division 01 for general submittal requirements.
B.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.04COORDINATION MEETINGS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.05REFERENCE STANDARDS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.06QUALITY ASSURANCE
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.07DELIVERY, STORAGE, AND HANDLING
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions, for project/site requirements.
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1.08NOMENCLATURE AND IDENTIFICATION
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.09WARRANTY
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.10PROJECT/SITE REQUIREMENTS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
2.00PRODUCTS (NOT USED)
3.00EXECUTION
3.01GENERAL REQUIREMENTS – TESTING
A.See execution requirements in Division 40, Section 40 61 00, Process Control and
Instrumentation Systems – General Provisions.
B.As part of the requirement of this Specification Section, it is the responsibility of the
PCSI/ASP to provide a complete operational control system. Confirmation of an operational
control system is dependent upon results derived from test procedures as specified in this
Section. The PCSI/ASP shall test all equipment at the factory prior to shipment. Unless
otherwise specified in the individual Specification Sections, all equipment provided by the
PCSI shall be tested at the factory as a single fully integrated system.
C.The PCSI/ASP shall test the system so that the OWNER/ENGINEER can verify all the points in
the existing control system. The PCSI/ASP shall coordinate testing of the Pre-Functional
Tests (PFT), Witness Factory Tests (WFT), Operational Readiness Tests (ORT) and Functional
Demonstration Tests (FDT) with the OWNER/ENGINEER.
D.At a minimum, the testing shall include the following, as noted in Section 40 61 00 and
Section 40 68 00:
1.Factory Testing
a.Unwitnessed Factory Test (UFT)
b.Witnessed Factory Test (WFT)
2.Testing of existing system
a.Pre-Functional Tests (PFT)
3.Field Testing
a.Operational Readiness Test (ORT)
b.Functional Demonstration Test (FDT)
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c.30-day Site Acceptance Test (SAT)
E.Each test shall be in the cause-and-effect format. The person conducting the test shall
initiate an input (cause) and, upon the system's or subsystem's producing the correct result
(effect), the specific test requirement will have been satisfied.
F.All tests shall be conducted in accordance with prior OWNER/ENGINEER approved
procedures, forms, and all checklists as submitted by the PCSI under Division 40, Section 40
61 00, Process Control and Instrumentation Systems – General Provisions, Part 1.3 and this
section. Each test to be performed shall be described and a space provided after it for sign-
off by the appropriate parties after its satisfactory completion. The PCSI shall include
“punchlist” forms with the test procedures to document issues that arise during the testing.
Punchlist forms, at a minimum, shall include a specification cross reference; an issues
description field; a resolution description field; and a sign-off area for the PCSI/ASP,
OWNER, and ENGINEER.
G.Copies of the signed-off test procedures, forms, and checklists will constitute the required
testing documentation. The test result forms shall be submitted to the OWNER/ENGINEER
for approval within 10 days of completion of each test.
H.The PCSI shall provide all special testing materials and equipment. Wherever possible,
perform tests using actual process variables, equipment, and data. Where it is not practical
to test with real process variables, equipment, and data, provide suitable means of
simulation. These simulation techniques shall be defined in the test procedures.
I.The PCSI/ASP shall coordinate all required testing with the CONTRACTOR, all affected
Subcontractors, the ENGINEER, and the OWNER.
J.The PCSI shall furnish the services of field service engineers, all special calibration and test
equipment, and labor to perform the field tests.
K.If testing is conducted more than 100 miles away from Corpus Christi, CONTRACTOR shall
include OWNER’s travel cost in their cost estimate.
L.The OWNER/ENGINEER reserves the right to test or retest all specified functions, whether
or not explicitly stated on the Test Procedures, as required, to determine compliance with
the functional requirements of the overall system. Such testing required to determine
compliance with the specified requirements shall be performed at no additional cost to the
OWNER. The OWNER/ENGINEER's decision shall be final regarding the acceptability and
completeness of all testing.
M.No equipment shall be shipped until the OWNER/ENGINEER has received all test results and
approved the system is ready for shipment.
N.Correction of Deficiencies
1.All deficiencies in workmanship and/or items not meeting specified testing
requirements shall be corrected to meet specification requirements at no additional
cost to the OWNER.
2.Testing, as specified herein, shall be repeated after correction of deficiencies is made
until the specified requirements are met. This work shall be performed at no
additional cost to the OWNER.
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3.02FACTORY TESTING - UNWITNESSED FACTORY TEST (UFT)
A.Prior to shipment of the equipment, the entire system, except primary elements, final
control elements, and field-mounted transmitters, shall be interconnected and tested to
ensure the system will operate as specified. All analog and discrete input/output points not
interconnected at this time shall be simulated to ensure proper operation of all alarms,
monitoring devices/functions, and control devices/functions.
B.All panels, consoles, and assemblies shall be inspected and tested to verify their
conformance with related submittals, Specifications, and Drawings.
C.During the tests, all digital system hardware and software shall be operated for at least five
days continuously without a failure to verify the system is capable of continuous operation.
D.Tests to be performed shall include, but not be limited to, the following. Each of these tests
shall be specifically addressed in the Test Procedure submittal.
1.All panels and enclosures being provided shall undergo a thorough inspection to verify
the integrity of the cabinet enclosures, frame structures, paint work and finish, etc.
Additionally, the PCSI shall review the panel drawings with the OWNER/ENGINEER to
ensure they accurately reflect the panel layout and wiring.
2.Panel wire pull tests shall be performed on all wiring to ensure it has been connected
to the appropriate torque to prevent wires from coming loose.
3.For panels provided in new enclosures, heat loading tests shall be performed to ensure
proper cooling/ventilation is being provided.
4.UPS’s shall be tested with all equipment connected to verify the UPS’s have been sized
correctly to maintain the specified run time at the specified loading.
5.An I/O point checkout of 100 percent of each I/O module shall be performed to verify
proper operation of the input/output points. The verification of the signals will be
accomplished via the use of the PLC programming software. At a minimum, the I/O
checkout shall consist of four steps.
a.Digital input signals shall be jumpered within the termination connections of the
PLC panels; and verification of proper alarming, statuses, etc., shall be performed
utilizing the tools available in the PLC programming software.
b.Analog input signals shall be connected to a signal generator at the termination
connections; and signals shall be verified at zero percent, 25 percent, 50 percent,
75 percent, and 100 percent of full scale. The appropriate scaled value shall be
verified utilizing the tools available in the PLC programming software.
c.Digital output signals shall be initiated by the user by writing to the signals
utilizing the PLC programming software. Verification shall occur in the PLC panel
by connecting a digital multimeter to measure the continuity at the terminations,
thus verifying the command from the PLC has properly executed the contact
closure.
d.Analog output signals shall be initiated by the user by writing to the signals
utilizing the PLC programming software. Verification shall occur in the PLC panel
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by utilizing a digital multimeter to measure the current/voltage generated at the
termination points.
E.All control panels provided or modified under the requirements of the related technical
specification sections of Division 40 shall be included in these tests.
F.Upon successful completion of the UFT, the PCSI shall submit a record copy of the test
results to the OWNER/ENGINEER and coordinate the scheduling of the WFT.
3.03FACTORY TESTING - WITNESSED FACTORY TEST (WFT)
A.Before scheduling the WFT, the PCSI/ASP shall determine through his own UFT and through
their internal quality assurance program that the equipment is ready for shipment to the
job site.
B.All system tests performed and specified for the UFT shall be repeated in the presence of
the OWNER/ENGINEER.
C.The WFT will be conducted at the PCSI/ASP’s facility. The PCSI/ASP shall notify the
OWNER/ENGINEER in writing that the system is ready for the WFT. The OWNER/ENGINEER
shall schedule a test date within 14 days of receipt of the “Ready to Test” letter. At the time
of notification, the PCSI/ASP shall submit any revisions to the detailed test procedure
previously approved by the OWNER/ENGINEER.
D.The purpose of the WFT is to verify the functionality, performance, and stability of the
hardware and software. The system must operate continuously throughout the WFT
without failure, except where initiated per the established test procedures. Any
unanticipated failures may, at the OWNER/ENGINEER’s option, result in the overall WFT
being deemed unsuccessful. Successful completion of the WFT, as determined by the
OWNER/ENGINEER, shall be the basis for approval of the system to be shipped to the job
site.
E.The various tests performed during the WFT shall be designed to demonstrate that
hardware and software fulfill all the requirements of the specifications and Contract
Drawings. The test conditions shall resemble as closely as possible the actual installed
conditions. Any additional hardware or software that may be required to successfully verify
system operation shall be supplied at no cost to the OWNER.
F.Tests to be performed during the WFT shall include, but not be limited to, the following:
1.Perform a system audit to verify all components have been staged for the test.
2.Inspect the system inventory to verify all components have been documented
properly with correct model numbers, serial numbers, etc.
3.For each hardware enclosure, inspection shall include, but not be limited to, cabinet
enclosures, frame structure, paint work and finish, dimensions, and hardware
operability (i.e., fans, door hinges, keylocks, etc.).
4.For each subpanel, inspection shall include, but not be limited to, I/O subsystem
physical layout, power supply sizing and mounting, cable routing, wire runs across
hinges properly installed, fans and blowers unobstructed and mounted to maximize air
flow, power conditioning correctly installed, and overall layout and installation of
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components meets manufacturer’s recommendations and standard industry-accepted
practices.
5.Demonstrate operability of all equipment.
6.100 percent point check of I/O, including wiring. Analog signals shall include
verification of zero percent, 25 percent, 50 percent, 75 percent, and 100 percent of
scale. Additionally, out-of-range testing (over and under scale) shall be accomplished.
7.Demonstrate the ability to monitor and change at least 20 pieces of digital and analog
data in each PLC from the HMI software at all operator workstations.
8.Demonstrate the ability to share data between operator workstations and servers.
9.Demonstrate the ability of each workstation to print reports on all designated network
report printers.
10.Demonstrate the ability for each workstation to read and write to and from designated
files from other workstations on the LAN.
11.Demonstrate the operability of all mass storage equipment.
12.Demonstrate communication failure and system restart.
13.Demonstrate total power failure and recovery. The UPS shall be removed for this test.
14.Demonstrate the failover capabilities of the redundant historical servers.
15.Demonstrate the failover capabilities of the redundant process control system servers.
16.Demonstrate the failover capabilities of the redundant PLCs.
17.Demonstrate the ability of the UPS's to meet the runtime requirements upon loss of
power.
18.Demonstrate logical failure conditions for control strategies (i.e., instrument failures,
equipment failures, loss of communication between the Process I/O Server and the
PLC, loss of peer-to-peer communication, etc.).
G.During the test, for a period of time equal to at least 20 percent of the test duration, the
OWNER/ENGINEER shall have unrestricted access to the system to perform any additional
testing desired or to re-test any previously tested components.
H.All analog control panels shall be included in these tests.
I.All deficiencies identified during these tests shall be corrected and re-tested prior to
completing the WFT as determined by the OWNER/ENGINEER.
J.The following documentation shall be made available to the OWNER/ENGINEER at the test
site both before and during the WFT:
1.All Contract Drawings and Specifications, addenda, and change orders.
2.Master copy of the test procedure.
3.Bill of material of the computer/PLC/LAN equipment and software to be tested
including make, model, and serial number.
4.Design-related hardware submittal applicable to the equipment being tested.
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5.Software licenses.
6.Software documentation submittal.
K.The daily schedule during these tests shall be as follows:
1.Morning meeting to review the day’s test schedule.
2.Scheduled tests and sign-offs.
3.End of day meeting to review the day’s test results and to review or revise the next
day’s test schedule.
4.Unstructured testing period by the witnesses.
L.All test data and procedures followed during testing shall be logged, and certified copies of
the logs shall be provided to the OWNER/ENGINEER.
3.04EXISTING STATION TESTING – PRE-FUNCTIONAL TEST (PFT)
A.Prior to installation of the process control system components for each PLC replacement
location and prior to startup, the system shall be tested (inspect and document
terminations, calibrations, loop functionality, field equipment functionality, and controls
functionality) as installed to document conditions prior to construction activities.
B.The PFT will be a joint test coordinated between the PCSI/ASP and OWNER. The PCSI shall
facilitate testing under the direction of OWNER personnel, and provide sufficient staff to
cover onsite PLC, HMI, and OIT inspections, and documentation.
C.Loop/Component Inspections and Tests: The entire system shall be checked on a loop-by-
loop and component-by-component basis.
1.The Loop/Component Inspections and Tests shall be implemented using
OWNER/ENGINEER approved forms and checklists. PCSI/ASP shall submit testing forms
for approval prior to testing.
a.Each loop shall have a Loop Status Report to organize and track its inspection.
These reports shall include the following information and check-off items with
spaces for sign-off by the CONTRACTOR and OWNER:
1)Project Name, site name, test date, PCSI/ASP name, and lead PCSI/ASP
technician name.
2)PLC name, PLC loop tags (arranged by input/output channel or type), PLC
loop description, PLC loop range, PLC loop HI/LO state, setpoint, etc.
3)Check-offs/sign-offs for the loop: Panel interface terminations; I/O interface
terminations; I/O signal operation; inputs/outputs operational
(received/sent, processed, adjusted); total loop operation; process controller
scaling and adjustment; and space for comments.
4)Total loop operation: Provide space for comments.
5)Equipment status: Provide space for comments.
D.Computer-Manual (i.e., Remote-Manual) start/stop, open/close commands of all devices
controlled by the SCADA system shall be verified by the PCSI/ASP during the PFT.
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E.Upon completion of each PFT, the PCSI/ASP shall submit a record copy of the test results to
the OWNER/ENGINEER and request the scheduling of construction activities for that
PLC/OIT.
3.05FIELD TESTING - OPERATIONAL READINESS TEST (ORT)
A.Following installation of the process control system components and prior to startup and
the Functional Demonstration Test, the entire system shall be certified (inspected, wired,
calibrated, tested, etc., and documented) that it is installed and ready for the ORT as
defined below.
B.Loop/Component Inspections and Tests: The entire system shall be checked for proper
installation, calibrated, and adjusted on a loop-by-loop and component-by-component
basis to ensure that it is in conformance with related submittals and these Specifications.
1.The Loop/Component Inspections and Tests shall be implemented using
OWNER/ENGINEER approved forms and checklists.
a.Each loop shall have a Loop Status Report to organize and track its inspection,
adjustment, and calibration. These reports shall include the following information
and check-off items with spaces for sign-off by the system supplier:
1)Project name, test date, PCSI name, and lead PCSI technician name.
2)Loop number.
3)Tag number for each component.
4)Check-offs/sign-offs for each component: Tag/identification; installation;
termination (wiring and tubing); scale, range, and setpoint as applicable; and
calibration/adjustment (four-point for analog, setpoint for switches) rising
and falling.
5)Check-offs/sign-offs for the loop: Panel interface terminations; I/O interface
terminations; I/O signal operation; inputs/outputs operational
(received/sent, processed, adjusted); total loop operation; process controller
scaling and adjustment; and space for comments.
6)Tag/identification.
7)Installation.
8)Termination – wiring.
9)Calibration/adjustment – Check-offs/sign-offs for the loop.
10)Panel interface terminations.
11)I/O interface terminations.
12)I/O signal operation.
13)Inputs/outputs operational: Received/sent, processed, and adjusted.
14)Total loop operation: Provide space for comments.
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b.Each active Analog subsystem element and each I/O module shall have a
Component Calibration Sheet. These sheets shall have the following information,
spaces for data entry, and a space for sign-off by the PCSI/ASP.
1)Project name.
2)Loop number.
3)Component tag number of I/O module number.
4)Component code number analog system.
5)Manufacturer (for Analog system element).
6)Model number/serial number (for Analog system).
7)Summary of functional requirements shall include, but not be limited to,
scale and chart ranges of indicators, recorders, and transmitters/converters;
functions of computing elements; and parameters of controllers (i.e.,
proportional, integral, derivative, reverse/forward acting, etc.).
a)Indicators: Scale.
b)Transmitters/Converters: Scale.
c)Computing Elements: Function.
d)Controllers: Action (direct/reverse) control Modes (PID).
e)Switching Elements: Unit range, differential (FIXED/ADJUSTABLE), Preset
(AUTO/MANUAL).
f)I/O Modules: Input or output.
2.Calibrations
a.Analog Devices: Required and actual inputs and outputs at 0, 25, 50, 75, and 100
percent of span, rising and falling.
b.Discrete Devices: Required and actual trip points and reset points.
c.Controllers: Mode settings (PID).
d.I/O Modules: Required and actual inputs or outputs for 0, 25, 50, 75, and 100
percent of span, rising and falling.
1)Provide space for comments.
2)Space for sign-off by the PCSI/ASP.
C.The PCSI shall maintain the Loop Status Reports sheets at the job site and make them
available to the OWNER/ENGINEER at any time.
D.These inspections, calibrations, and tests do not require witnessing. However, the
OWNER/ENGINEER will review Loop Status Sheets and spot check the PCSI test process
periodically. Any deficiencies found shall be corrected by the PCSI prior to commencement
of the Functional Acceptance Test.
E.Prior to checkout of the I/O to the HMI, the PCSI shall thoroughly test all I/O from the field
device to the PLC terminals, and verify the PLC is powered up and the PLC is communicating
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to the SCADA servers. After the PCSI has successfully tested all I/O from the field devices to
the PLC terminals, the PCSI/ASP shall test all I/O from the HMI to the field device. Should
this test prove to be unsuccessful, the PCSI/ASP shall test from the HMI to the terminations
located in the OWNER’s termination cabinet, and the PCSI/ASP shall inform the OWNER in
writing of the discrepancy with the existing field wire.
F.Computer-Manual (i.e., Remote-Manual) start/stop, open/close commands of all devices
controlled by the SCADA system shall be verified by the PCSI/ASP during the ORT.
G.For all panels with enclosures (new and existing) modified by this Contract, heat load tests
shall be performed to ensure proper cooling/ventilation is being provided.
H.Upon successful completion of the ORT, the PCSI/ASP shall submit a record copy of the test
results to the OWNER/ENGINEER and request the scheduling of the FDT as noted in the
following section.
3.06FIELD TESTING - FUNCTIONAL DEMONSTRATION TEST (FDT)
A.Prior to startup and the 30-day Site Acceptance Test, the entire installed instrument and
control system shall be certified that it is ready for operation. All preliminary testing,
inspection, and calibration shall be complete as defined in the ORT. The FDT will be a joint
test by the PCSI and the equipment suppliers. PCSI shall coordinate with OWNER
inspections to allow for OWNER presence during this test.
B.Once a process area has been started up and is operating, a witnessed FDT shall be
performed on that system to demonstrate that it is operating and is in compliance with
these Specifications. A witnessed FDT shall be performed on each process area. Each
specified function shall be demonstrated on a paragraph-by-paragraph, loop-by-loop, and
site-by-site basis.
C.Loop-specific and non-loop-specific tests shall be the same as specified under WFT, except
that the entire installed system shall be tested and all functions demonstrated using live
field-based data to the greatest extent possible.
D.Updated versions of the documentation specified to be provided for during the factory
tests shall be made available to the OWNER/ENGINEER at the job site both before and
during the tests. In addition, one copy of all O&M Manuals shall be available for reference
at the job site, both before and during testing.
E.The daily schedule specified to be followed during the factory tests shall also be followed
during the FDT.
F.During the FDT, a demonstration of communication failure and recovery shall be
accomplished. This test shall be scheduled and coordinated with OWNER’s personnel to
minimize the impact on plant operations.
G.Following initial startup, the entire process control system shall operate for a continuous
100 hours without failure before this test will be started.
H.Punchlist items and resolutions noted during the test shall be documented on the
Punchlist/Resolution form. In the event of rejection of any part or function test procedure,
the PCSI shall perform repairs, replacement, and/or retest within 10 days.
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I.Upon successful completion of the FDT, the PCSI/ASP shall submit a record copy of the test
results to the OWNER/ENGINEER and request the scheduling of the SAT as noted in the
following section.
3.07FIELD TESTING - 30-DAY SITE ACCEPTANCE TEST (SAT)
A.After completion of the Operational Readiness and Functional Demonstration Tests, the
PCSI shall be responsible for operation of the entire system for a period of 30 consecutive
days (Site Acceptance Test – SAT), under conditions of full plant process operation, without
a single non-field-repairable malfunction.
B.During this test plant operation, PCSI/ASP personnel shall be present as required to address
any potential issues that would impact the overall system operation. The PCSI/ASP are
expected to provide personnel for this test who have an intimate knowledge of the
hardware, software, field wiring, and network configuration of the system. The PCSI/ASP is
also expected to provide personnel for this test who have an intimate knowledge of the
software programming of the system. When PCSI/ASP personnel are not on site, the
PCSI/ASP shall provide cell phone/pager numbers that OWNER personnel can use to ensure
that support staff is available by phone and/or on site within four hours of a request by
operations staff.
C.While this test is proceeding, the OWNER/ENGINEER shall have full use of the system. Only
plant operating personnel shall be allowed to operate equipment associated with live plant
processes. Plant operations shall remain the responsibility of OWNER, and the decision of
plant operators regarding plant operations shall be final.
D.Any malfunction during the tests shall be analyzed and corrections made by the PCSI/ASP
for programming, hardware, software, field wiring, and network configuration issues. The
OWNER/ENGINEER will determine whether any such malfunctions are sufficiently serious
to warrant a repeat of this test.
E.Any malfunction during this 30 consecutive day test period which cannot be corrected by
the PCSI/ASP personnel within 24 hours of occurrence, or more than two similar failures of
any duration, will be considered as a non-field-repairable malfunction.
F.Upon completion of repairs by the PCSI/ASP, the SAT will be re-started from the date which
the PCSI/ASP successfully corrected the malfunction(s) and the OWNER/ENGINEER have
accepted and signed off on the repairs.
G.The PCSI/ASP shall perform repairs or replacement within 10 days in the event of rejection
of any part or function of the hardware, software, field wiring, and network configuration
systems.
H.All database, process controller logic, and graphical interface system errors must be
functioning as required per the specifications prior to the start of each test period. The 30-
day test will not be considered successful until all database points and logic functions are
tested and verified to be correct.
I.The total availability of the system shall be greater than 99.5 percent (99.5%) during this
test period. Availability shall be defined as:
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Availability in percent = 100 * (Total Testing Time – Down Time) / Total Testing Time
J.Down times due to power outages or other factors outside the normal protection devices
or backup power supplies provided shall not contribute to the availability test times above.
K.Throughout the duration of the 30-day SAT, no software or hardware modifications shall be
made to the system without prior approval from the OWNER/ENGINEER.
L.Upon successful completion of the 30-day operation test and subsequent review and
approval of complete system final documentation, the system shall be considered
substantially complete and the warranty period shall commence.
M.Certification of Installation: Following successful completion of the 30-day test, the
PCSI/ASP shall issue a Certification of Installation. Certification shall be on PCSI/ASP
corporate letterhead and signed by an officer of the firm. Certification shall state that the
process control system has been completed in conformance with plans and specifications.
Certification shall be submitted to the OWNER/ENGINEER as specified herein.
3.08ATTACHMENTS
A.The following Section Attachments are included to provide further details and
requirements for testing. Data within is not specific to this project. It is provided as an
example.
1.Attachment A – Standard Testing Forms – I/O Testing.
END OF SECTION
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This PLC is a new Schneider SCADApack 474 Remote Telemetry Unit located at the XXXX Pump
Station. The new PLC will be designed to match the type and quantity of existing field I/O plus
additional I/O but utilizing a modern Schneider SCADAPack control platform. The intent is to design
the new PLC as a complete replacement for the existing Motorola ACE3600 PLC and I/O racks.
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There is one (1) Schneider Remote Telemetry Unit Control Cabinet that consists of an AC power
source, a DC power source, an RTU, field I/O modules, and communication modules (among other
devices). The power sources, the RTU, and its peripheral modules are remotely monitored from the
plant SCADA system. The RTU cabinet has a graphic user interface touch screen installed on the
front with the capability to monitor and control all equipment and instrumentation at the Pump
Station. Additionally, there is (1) Phonix Contact 24 V DC power supply.
The XXXX Pump Station delivers water to the Low Side local pressure zone. Water from the
pressure zone is supplied to the high-service pumps located inside the existing High Service Pump
Station Building. The pump station in turn help maintain the level in the XXXX and XXXX Elevated
Storage Tanks. The pump station is equipped with four constant speed HSPs.
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Page 8
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The XXXX Pump Station is equipped with four constant speed HSPs. Each pump has a discharge
valve that is hardwired interlocked with the HSP control circuitry. When the HSP is commanded to
operate, the pump starts, and the discharge valve is commanded to open. When running and the
pump is requested to stop, the valve is commanded to close. When the valve is confirmed closed,
the HSP is requested to stop.
Whenever an HSP is operating in any mode, a minimum GST level is required. When the GST Level
drops below an operator adjustable Low-Level Lockout Setpoint (after a deadband of 20 seconds),
an alarm is generated at the PLC notifying the operator of a Low-Level GST condition. Whenever an
HSP is running in the Remote Manual or Automatic Mode and the Low-Level GST condition is
present, the HSPs are commanded to normally stop and soft locked out from operation. Once the
Level rises above the Low-Level GST Reset Setpoint, (after a deadband of 20 seconds), the control
system will release the pumps to be available for use. The Five Million Gallon (5MG) Ground
Storage Tank and One Million Gallon (1MG) Ground Storage Tank levels are monitored with a low
level in either tank initiating a stop of the pumps. To prevent a lockout from occurring, the operator
may also Override the Low Level Cut off from the Control System HMI.
Each pump’s running status is used to calculate the equipment runtimes. There are two sets of
values that are tracked: Starts and Daily Runtime. These values are historized and are reset daily.
For the purposes of this test, it is assumed the independent local control panel is operating
correctly. This test will not verify the operability of the local controls.
2.2.1.2,®¢ « #®³±®«
Each HSP has Local Manual Control capability at the Pump MCC. To allow Local Manual Control of
an HSP at the Pump MCC. The operator must place the HOA switch in its Hand Position. This will
start the HSP at the Pump MCC.
2.2.1.3 2¤¬®³¤ - ´ « #®³±®«
Each HSP has Remote Manual Control capability at the HMI.
To allow Remote Manual Control of an HSP at the HMI, the operator must place the HOA switch in
its AUTO Position and place the HSP control mode at the HMI in the Remote Manual Mode. The
operator may then remotely start and stop the HSP at the HMI by clicking on the HSP symbol and
selecting START or STOP commands on the HMI.
2.2.1.4 2¤¬®³¤ !´³®¬ ³¨¢ #®³±®«
To allow Remote Automatic Control of an HSP at the HMI, the operator must place the HOA switch
in its AUTO Position and place the HSP control mode at the HMI in the Remote Automatic Mode.
The automatic control scheme will be based on a level control scheme where the operator is able to
both set the ON and OFF level setpoints for each operating pump. Additionally, the operator selects
one of two tank levels that the control scheme will operate on.
The XXXX Pump Station receives the EST levels from both XXXX EST and XXXX EST via SCADA
Modbus Communications. The operator selects whether XXXX EST or XXXX EST will be the level the
control scheme will be trying to maintain. In the event of a communication failure between the “In
Control” EST, the pump station will continue to operate off the last known good value. If the level
signal be determined to be invalid, then an alarm is generated at the PLC, sent to the HMI notifying
plant operators of the signal loss and that the remote automatic control strategy is holding the last
known valid level.
Each Pump will have a unique On Setpoint, once the tank level drops below the On Setpoint, the
pump will be called to run. The setpoints are configured in such a way that run setpoints are not
allowed to be within 1.999 Feet of each other. If a value is provided that is within 1.999 Feet, the
setpoint will be rejected, and the existing setpoint will stay active.
When in Remote Automatic Mode, the HSPs are required to run based on the automatic strategy
and are sequenced on after time delays. The design intent is to keep multiple HSPs from starting at
the same time. A minimum of 20 seconds between pump starts is to be accounted for in the design.
Each Pump will have an Off Setpoint, once the tank level rises above the Off Setpoint, the pump will
be called to stop. Note that pumps can share the same Off Setpoint value unlike the On Setpoints.
Only one XXXX pump station operates at a time. As a result, whenever a pump at XXXX is running,
all Automatic Setpoints and LLCO settings are transferred over to XXXX. Whenever a pump at XXXX
is running, all Automatic Setpoints and LLCO settings are transferred over to XXXX. This transfer of
data takes place through System Platform objects (it is not PLC 2 PLC).
2.2.23¯¤¢¨¥¨¢ ³¨® 2¤¥¤±¤¢¤
None.
2.2.3!¯¯«¨¢ ¡«¤ )²³±´¬¤³²
XXXX EST Level Instrument
XXXX EST Level Instrument
2.2.4!¯¯«¨¢ ¡«¤ %°´¨¯¬¤³
High Service Pump #1
High Service Pump #2
High Service Pump #3
High Service Pump #4
High Service Pump #1 Discharge Valve
High Service Pump #2 Discharge Valve
High Service Pump #3 Discharge Valve
High Service Pump #4 Discharge Valve
2.2.50¤±¬¨²²¨µ¤²
For the HSPs to start, the following permissives must be met:
The control switches must be switched to the correct positions for each control mode.
2.2.6)³¤±«®¢ª²
The HSPs must shut down if the following conditions are active:
The Emergency Stop pushbutton at the HSP Motor Starter is triggered.
The GST minimum Low-Low Level is triggered.
If the HSP is called to run and the associated discharge valve does not open within a time set
by a timer relay, an incomplete sequence alarm is triggered. This alarm interlocks the pump.
2.2.73#!$! )³¤±¥ ¢¤
The independent control panel is monitored by the RTU. The RTU in turn sends a signal to the
graphic interface indicating the following statuses for each pump:
Pump On/Off status.
Pump HOA Switch Control Status.
Pump Load Amps
Pump Daily Runtime
Pump Daily Starts
Valve Open Status
Valve Closed Status
2.2.8$¤µ¨ ³¨®²
None.
2.2.94¤²³ 0±®¢¤£´±¤² Ȩ²³¤¯ȃ¡¸ȃ²³¤¯ȩ
2.2.9.1 2¤¬®³¤ - ´ « #®³±®« ȟ (¨¦§ 3¤±µ¨¢¤ 0´¬¯
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the equipment is stopped, its
respective discharge valve is fully closed, its faults are cleared, and its
permissives are met. This test procedure assumes local HOA switch is in
,®¢ «ȁ The equipment is assumed to be in Manual mode.
Verify the Valve is Closed by confirming the color of the symbol is red on the
1process screen. On the equipment pop-up, the valve should indicate Closed.
Verify the pump is stopped by confirming the color of the symbol is red on
the process screen. On the equipment pop-up, the pump should indicate
stopped. The HOA Status indication on the equipment pop-up should read
Local. V erify the HSP is available for control by confirming the state
description on the equipment pop-up reads Available.
4¤²³Ȁ Place High Service Pump #1 in Remote Manual control mode.
&¨¤«£ !¢³¨®Ȁ From the MCC, place the HOA handswitch into “Auto” position.
2
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the state description on the equipment pop-up
transitions from Local on the process screen to Remote.
4¤²³Ȁ Turn on the pump manually using Remote controls
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Start” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state description
transitions from Closed to Transition on the equipment pop-up.
3
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the HSP is running by confirming the color of
the symbol changes to green on the process screen and the state description
on the equipment pop-up reads running.
4¤²³ #«¤ ȃ5¯Ȁ Turn off the pump manually using remote controls
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Open” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ 6 erify the HSP is stopped by confirming the color of the
4
symbol changes to red on the process screen and the state description on the
equipment pop-up reads stopped.
Verify the discharge valve symbol transitions from green on the process
screen to yellow on the process screen. Verify the state description
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
transitions from Opened on the process screen to Transition on the
equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up.
2.2.9.2)³¤±«®¢ª ȟ ,®¶ 7 ³¤± #´³®¥¥
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the equipment is stopped, its
respective discharge valve is fully closed, its faults are cleared, and its
permissives are met. This test procedure assumes local HOA switch is in
,®¢ «ȁ The equipment is assumed to be in Manual mode. This test procedure
assumes the current tank level is above the Low-Level Cutoff Setpoint.
Verify the Valve is Closed by confirming the color of the symbol is red on the
process screen. On the equipment pop-up, the valve should indicate Closed.
Verify the pump is stopped by confirming the color of the symbol is red on
the process screen. On the equipment pop-up, the pump should indicate
stopped. The HOA Status indication on the equipment pop-up should read
Local. V erify the HSP is available for control by confirming the state
1
description on the equipment pop-up reads Available.
Note the GST level value and Low-Level Cutoff Setpoint:
5MG GST Level –_ _________ _______ feet
5MG Low-Level Cutoff SP –__________ _______ feet
1MG GST-Level –_ ____ _____ _______ feet
1MG Low Level Cutoff SP –__________ _______ feet
4¤²³Ȁ Place High Service Pump #1 in Remote Manual control mode.
&¨¤«£ !¢³¨®Ȁ From the MCC, place the HOA handswitch into “Auto” position.
2
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the state description on the equipment pop-up
transitions from Local on the process screen to Remote.
4¤²³Ȁ Turn on the pump manually using Remote controls
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Start” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state description
transitions from Closed to Transition on the equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to
3
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the HSP is running by confirming the color of
the symbol changes to green on the process screen and the state description
on the equipment pop-up reads running.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
4¤²³Ȁ Activate the 5MG GST Low-Level Cutoff Interlock
&¨¤«£ !¢³¨®Ȁ On the process screen, change the 5MG GST low-level cutoff
setpoint to read two (2) feet above the current level.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarm is generated by confirming the color of the
symbol is red on the process screen and local pop-up.
Verify the HSP is stopped by confirming the color of the symbol changes to
red on the process screen and the state description on the equipment pop-up
4
reads stopped. Verify the HSP is unavailable for control by confirming the
state description on the equipment pop-up reads Unavailable.
Verify the discharge valve symbol transitions from green on the process
screen to yellow on the process screen. Verify the state description
transitions from Opened on the process screen to Transition on the
equipment pop-up. Verify the valve symbol transitions from yellow on the
process screen to red on the process screen. Verify the state description
transitions from Transition to Closed on the equipment pop-up.
4¤²³Ȁ Restore 5MG GST Low Level Cutoff Alarm
&¨¤«£ !¢³¨®Ȁ On the process screen, change the 5MG GST low-level cutoff
setpoint to the original level cutoff setpoint. Change the low-level reset to be
below current tank level.
5
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarm that the alarm remains latched by
confirming the color of the symbol remains red on the process screen and
local pop-up.
4¤²³ #«¤ ȃ5¯Ȁ Place alarm in its normal operating condition following the
test and make pump available for control
&¨¤«£ !¢³¨®Ȁ From the HMI, acknowledge the alarm.
6
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarm is cleared by confirming the color of the
symbol is grey on the process screen and local pop-up. Verify the HSP is
available for control by confirming the state description on the equipment
pop-up reads Available.
Repeat steps 3-6 for the 1MG GST Low-Level Cutoff Interlock
7
Repeat steps 1-7 for the following devices:
HSP #2
8
HSP #3
HSP #4
2.2.9.3)³¤±«®¢ª /µ¤±±¨£¤ ȟ ,®¶ 7 ³¤± #´³®¥¥
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the equipment is stopped, its
respective discharge valve is fully closed, its faults are cleared, and its
permissives are met. This test procedure assumes local HOA switch is in
,®¢ «ȁ The equipment is assumed to be in Manual mode.
Verify the Valve is Closed by confirming the color of the symbol is red on the
process screen. On the equipment pop-up, the valve should indicate Closed.
Verify the pump is stopped by confirming the color of the symbol is red on
the process screen. On the equipment pop-up, the pump should indicate
stopped. The HOA Status indication on the equipment pop-up should read
Local. V erify the HSP is available for control by confirming the state
description on the equipment pop-up reads Available.
1
From the site process screen, click on the ALARM button to open up a pop-up
screen. Verify the alarms are cleared and low-level cutoff alarm is greyed out.
Note the GST level value and Low-Level Cutoff Setpoint:
5MG GST Level –_ _________ _______ feet
5MG Low-Level Cutoff SP –__________ _______ feet
1MG GST-Level –_ ____ _____ _______ feet
1MG Low Level Cutoff SP –__________ _______ feet
4¤²³Ȁ Confirm 5MG GST Low-Level Cutoff Bypass is operational
&¨¤«£ȝ #®³±®« 2®®¬ !¢³¨®Ȁ Set the 5MG GST Low-Level Cutoff Override
switch to ON.
2
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the override switch is set to ON by confirming the
symbol is set to ON on the local pop-up.
4¤²³Ȁ Place High Service Pump #1 in Remote Manual control mode.
&¨¤«£ !¢³¨®Ȁ From the MCC, place the HOA handswitch into “Auto”.
3
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the state description on the equipment pop-up
transitions from Local on the process screen to Remote.
4¤²³Ȁ Turn on the pump manually using Remote controls
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Start” button.
4
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state description
transitions from Closed to Transition on the equipment pop-up.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the HSP is running by confirming the color of
the symbol changes to green on the process screen and the state description
on the equipment pop-up reads running.
4¤²³Ȁ Attempt to trigger 5MG GST Low-Level Cutoff Interlock
&¨¤«£ !¢³¨®Ȁ From process screen, change the low-level cutoff setpoint to
read two (2) feet above the current level to attempt to trigger the 5MG GST
Low-Level Cutoff alarm.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarm that the alarm remains cleared by
5
confirming the color of the symbol remains grey on the process screen and
local pop-up.
Verify the HSP continues to run by confirming the color of the symbol is
green on the process screen and the state description on the equipment pop-
up reads running.
4¤²³Ȁ Activate the 5MG GST Low-Level Cutoff Interlock
&¨¤«£ !¢³¨®Ȁ Set the 5MG GST Low-Level Cutoff Override switch to OFF.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the override switch is set to OFF by confirming the
symbol is set to OFF on the local pop-up. Verify the alarm is generated by
confirming the color of the symbol is red on the process screen and local pop-
up.
Verify the HSP is stopped by confirming the color of the symbol changes to
red on the process screen and the state description on the equipment pop-up
6
reads stopped.
Verify the discharge valve symbol transitions from green on the process
screen to yellow on the process screen. Verify the state description
transitions from Opened on the process screen to Transition on the
equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up.
4¤²³Ȁ Restore 5MG GST Low Level Cutoff Alarm
&¨¤«£ !¢³¨®Ȁ On the process screen, change the 5MG GST low-level cutoff
7
setpoint to the original level cutoff setpoint. Change the low-level reset to be
below current tank level.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarm that the alarm remains latched by
confirming the color of the symbol remains red on the process screen and
local pop-up.
4¤²³ #«¤ ȃ5¯Ȁ Place alarm in its normal operating condition following the
test and make pump available for control
&¨¤«£ !¢³¨®Ȁ From the HMI, acknowledge the alarm.
8
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarm is cleared by confirming the color of the
symbol is grey on the process screen and local pop-up. Verify the HSP is
available for control by confirming the state description on the equipment
pop-up reads Available.
Repeat steps 3-8 for the 1MG GST Low-Level Cutoff Interlock
9
2.2.9.4$¨²¢±¤¯ ¢¸ 4¤²³¨¦ ȟ & ¨«ȃ³®ȃ3³ ±³
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the equipment is stopped, its
respective discharge valve is fully closed, its faults are cleared, and its
permissives are met. This test procedure assumes local HOA switch is in
2¤¬®³¤ȁ The equipment is assumed to be in Manual mode.
Verify the Valve is Closed by confirming the color of the symbol is red on the
process screen. On the equipment pop-up, the valve should indicate Closed.
1
Verify the pump is stopped by confirming the color of the symbol is red on
the process screen. On the equipment pop-up, the pump should indicate
stopped. The HOA Status indication on the equipment pop-up should read
Remote. V erify the HSP is available for control by confirming the state
description on the equipment pop-up reads Available.
4¤²³Ȁ Verify the discrepancy timer functionality.
&¨¤«£ !¢³¨®Ȁ Set the Discrepancy Timer SP to 15 seconds. In the RTU, force
the “Running” digital input to OFF. From the equipment pop-up, press the
“Start” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state description
transitions from Closed to Transition on the equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the HSP is not running by confirming the
color of the symbol remains red on the process screen and the state
description on the equipment pop-up reads stopped.
2
Verify the Discrepancy Time remaining in the RTU counts down. Allow for the
Discrepancy Timer to expire in the RTU. From the process screen, equipment
pop-up, and the alarm summary, verify the equipment Discrepancy alarm is
active.
Verify the discharge valve symbol transitions from green on the process
screen to yellow on the process screen. Verify the state description
transitions from Opened on the process screen to Transition on the
equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up.
V erify the HSP is unavailable for control by confirming the state description
on the equipment pop-up reads Unavailable.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
4¤²³ #«¤ ȃ5¯Ȁ Restore pump functionality.
&¨¤«£ !¢³¨®Ȁ Acknowledge the alarm. Set the Discrepancy Timer SP to the
original setpoint. Click the Fail Reset Command. Remove the force from the
“Running” signal in the RTU.
3
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarms have cleared. V erify the HSP is available
for control by confirming the state description on the equipment pop-up
reads Available.
Repeat steps 1-3 for the following devices:
HSP #2
4
HSP #3
HSP #4
2.2.9.5$¨²¢±¤¯ ¢¸ 4¤²³¨¦ ȟ & ¨«ȃ³®ȃ3³®¯
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the equipment is stopped,
its respective discharge valve is fully closed, its faults are cleared, and
its permissives are met. This test procedure assumes local HOA switch
is in !´³®ȁ The equipment is assumed to be in Manual mode.
Verify the Valve is Closed by confirming the color of the symbol is red
on the process screen. On the equipment pop-up, the valve should
1
indicate Closed. Verify the pump is stopped by confirming the color
of the symbol is red on the process screen. On the equipment pop-up,
the pump should indicate stopped. The HOA Status indication on the
equipment pop-up should read Remote. V erify the HSP is available for
control by confirming the state description on the equipment pop-up
reads Available.
4¤²³Ȁ Turn on the pump manually using Remote controls
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Start” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state
description transitions from Closed to Transition on the equipment
pop-up.
2
Verify the valve symbol transitions from yellow on the process screen
to green on the process screen. Verify the state description transitions
from Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the HSP is running by confirming the
color of the symbol changes to green on the process screen and the
state description on the equipment pop-up reads Running.
4¤²³Ȁ Verify the discrepancy timer functionality.
&¨¤«£ !¢³¨®Ȁ Set the Discrepancy Timer SP to 15 seconds. In the RTU,
force the “Running” digital input to ON. From the equipment pop-up,
press the “Stop” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the discharge valve symbol transitions from
3
green on the process screen to yellow on the process screen. Verify
the state description transitions from Opened on the process screen
to Transition on the equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen
to red on the process screen. Verify the state description transitions
from Transition to Closed on the equipment pop-up.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
Once the valve is closed, verify the HSP is running by confirming the
color of the symbol continues to be green on the process screen and
the state description on the equipment pop-up reads Running.
Verify the Discrepancy Time remaining in the RTU counts down. Allow
for the Discrepancy Timer to expire in the RTU. From the process
screen, equipment pop-up, and the alarm summary, verify the
equipment Discrepancy alarm is active.
V erify the HSP is unavailable for control by confirming the state
description on the equipment pop-up reads Unavailable.
4¤²³ #«¤ ȃ5¯Ȁ Restore pump functionality
&¨¤«£ !¢³¨®Ȁ Acknowledge the alarm. Set the Discrepancy Timer SP to
the original setpoint. Click the Fail Reset Command. In the RTU,
remove the force from the “Running” digital input.
4
%·¯¤¢³¤£ 2¤²´«³Ȁ 6 erify the HSP is stopped by confirming the color of
the symbol changes to red on the process screen and the state
description on the equipment pop-up reads stopped. V erify the HSP is
available for control by confirming the state description on the
equipment pop-up reads Available.
Repeat steps 1-4 for the following devices:
HSP #2
5
HSP #3
HSP #4
2.2.9.6 2¤¬®³¤ !´³®¬ ³¨¢ #®³±®«
The following test procedures are to be used for the remote automatic control testing of the high
service pumps. It is important to note that during operational readiness testing (ORT) and
functional demonstration testing (FDT), the amount of water in the ground storage tank may not
permit all pumps to function according to the procedure listed below. For this reason, some of the
steps in the following procedures may need to be skipped.
Note: At the time of the test, the communications between XXXX and XXXX Pump Station is not set
up and this will be the value that is manipulated at the time of the test.
2.2.9.6.1Remote Automatic Control – High Service Pumps
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the equipment is stopped, its
respective discharge valve is fully closed, its faults are cleared, and its
permissives are met. This test procedure assumes local HOA switch is in
!´³®ȁ The equipment is assumed to be in Manual mode. Control of the tank is
selected to be reading XXXX EST level.
Verify the Valve is Closed by confirming the color of the symbol is red on the
process screen. On the equipment pop-up, the valve should indicate Closed.
Verify the pump is stopped by confirming the color of the symbol is red on
the process screen. On the equipment pop-up, the pump should indicate
stopped. The HOA Status indication on the equipment pop-up should read
Remote. V erify the HSP is available for control by confirming the state
description on the equipment pop-up reads Available.
From the process screen, click the pump pushbutton to open the pump
control pop-up. Verify the following ‘START’ and ‘STOP’ level setpoints for
each pump:
1
HSP Lead Pump Start Level Setpoint = _ ________
HSP Lag1 Pump Start Level Setpoint = _ ________
HSP Lag2 Pump Start Level Setpoint = _ ________
HSP Lag3 Pump Start Level Setpoint = _ ________
HSP Lead Pump Stop Level Setpoint = _ ________
HSP Lag1 Pump Stop Level Setpoint = _ ________
HSP Lag2 Pump Stop Level Setpoint = _ ________
HSP Lag3 Pump Stop Level Setpoint = _ ________
4¤²³Ȁ Place High Service Pumps in Remote Automatic control mode.
2
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up for each motor, place the
handswitch into “Auto” position.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the state description on the equipment pop-up
transitions from Manual on the process screen to Auto.
4¤²³Ȁ Turn on the Lead pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value below the Lead Pump
Start Level Setpoint from the PLC program.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol on the Lead Pump transitions from
red on the process screen to yellow on the process screen. Verify the state
description transitions from Closed to Transition on the equipment pop-up.
3
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the Lead HSP is running by confirming the
color of the symbol changes to green on the process screen and the state
description on the equipment pop-up reads running. No other pump should
be running.
4¤²³Ȁ Turn on the Lag1 pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value below the Lag1 Pump
Start Level Setpoint from the PLC program.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol on the Lag1 Pump transitions from
red on the process screen to yellow on the process screen. Verify the state
description transitions from Closed to Transition on the equipment pop-up.
4
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the Lag1 HSP is running by confirming the
color of the symbol changes to green on the process screen and the state
description on the equipment pop-up reads running. Verify Lag2 and Lag3
pumps are not running.
4¤²³Ȁ Turn on the Lag2 pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value below the Lag2 Pump
Start Level Setpoint from the PLC program.
5
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol on the Lag2 Pump transitions from
red on the process screen to yellow on the process screen. Verify the state
description transitions from Closed to Transition on the equipment pop-up.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the Lag2 HSP is running by confirming the
color of the symbol changes to green on the process screen and the state
description on the equipment pop-up reads running. Verify Lag3 pump is not
running.
4¤²³Ȁ Turn on the Lag3 pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value below the Lag3 Pump
Start Level Setpoint from the PLC program.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol on the Lag3 Pump transitions from
red on the process screen to yellow on the process screen. Verify the state
description transitions from Closed to Transition on the equipment pop-up.
6
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Once the valve is opened, verify the Lag3 HSP is running by confirming the
color of the symbol changes to green on the process screen and the state
description on the equipment pop-up reads running.
4¤²³Ȁ Turn off the Lag3 pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value above the Lag3 Pump
Stop Level Setpoint from the PLC program.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the Lag3 HSP is stopped by confirming the color of
the symbol changes to red on the process screen and the state description on
the equipment pop-up reads stopped.
Verify the discharge valve symbol on the Lag3 Pump transitions from green
7
on the process screen to yellow on the process screen. Verify the state
description transitions from Opened on the process screen to Transition on
the equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up. Verify the other pumps
continue to run.
4¤²³Ȁ Turn off the Lag2 pump using Auto controls
8
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value above the Lag2 Pump
Stop Level Setpoint from the PLC program.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the Lag2 HSP is stopped by confirming the color of
the symbol changes to red on the process screen and the state description on
the equipment pop-up reads stopped.
Verify the discharge valve symbol on the Lag2 Pump transitions from green
on the process screen to yellow on the process screen. Verify the state
description transitions from Opened on the process screen to Transition on
the equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up. Verify Lag1 and Lead HSP
pumps continue to run.
4¤²³Ȁ Turn off the Lag1 pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value above the Lag1 Pump
Stop Level Setpoint from the PLC program.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the Lag1 HSP is stopped by confirming the color of
the symbol changes to red on the process screen and the state description on
the equipment pop-up reads stopped.
Verify the discharge valve symbol on the Lag1 Pump transitions from green
9
on the process screen to yellow on the process screen. Verify the state
description transitions from Opened on the process screen to Transition on
the equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up. Verify Lead HSP pumps
continues to run.
4¤²³Ȁ Turn off the Lead pump using Auto controls
&¨¤«£ !¢³¨®Ȁ Force the XXXX EST tank level to a value above the Lead Pump
Stop Level Setpoint from the PLC program.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the Lead HSP is stopped by confirming the color of
the symbol changes to red on the process screen and the state description on
10
the equipment pop-up reads stopped.
Verify the discharge valve symbol on the Lead Pump transitions from green
on the process screen to yellow on the process screen. Verify the state
description transitions from Opened on the process screen to Transition on
the equipment pop-up.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up.
4¤²³ #«¤ ȃ5¯Ȁ Place High Service Pumps in Remote Manual control mode.
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up for each motor, place the
handswitch into “Manual” position.
11
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the state description on the equipment pop-up
transitions from Auto on the process screen to Manual.
2.2.9.7 3³ ±³²ȝ 2´ 4¨¬¤ ȟ 0´¬¯
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the pump is Stopped
Verify the pump is Stopped by confirming the color of the symbol is red on
the process screen and on the pump status light located on the equipment
pop-up and is Stopped in the field. The HOA Status light on the equipment
pop-up should be green.
1
Note the total runtime and total starts accumulated values.
High Service Pump #1 – Daily Run Time _________________
High Service Pump #1 – Daily Starts _________________
4¤²³Ȁ Confirm the run time and accumulated starts are operating correctly
&¨¤«£ !¢³¨®Ȁ From the local independent control panel, place the
equipment’s HOA switch in ‘Hand’ to force the pump to run.
2
%·¯¤¢³¤£ 2¤²´«³Ȁ The color of the pump symbol should turn green on the
process screen and the pump status light should turn green on the pop-up.
The total runtime should increment according to the time spent running.
Total starts accumulated values should increment by one.
4¤²³ #«¤ ȃ5¯Ȁ Place pump control in its normal operating condition
&¨¤«£ !¢³¨®Ȁ From the local independent control panel, place the
equipment’s HOA switch in ‘Auto’.
3
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the pump is Stopped by confirming the color of the
symbol is red on the process screen and on the pump status light located on
the equipment pop-up and is Stopped in the field. The HOA Status light on
the equipment pop-up should be green.
Repeat steps 1-2 for the following devices: Pump #2, Pump #3, and Pump #4
High Service Pump #2 – Daily Run Time _________________
High Service Pump #2 – Daily Starts _________________
High Service Pump #3 – Daily Run Time _________________
4
High Service Pump #3 – Daily Starts _________________
High Service Pump #4 – Daily Run Time _________________
High Service Pump #4 – Daily Starts _________________
2.3'¤¤± ³®± 3³ ³´² £ !« ±¬²
2.3.13³± ³¤¦¸ $¤²¢±¨¯³¨®Ȁ
2.3.1.1/µ¤±µ¨¤¶
The XXXX Lift Station has a generator to operate the lift station in case of a loss of grid power.
Each pump’s running status is used to calculate the equipment runtimes. There are two sets of
values that are tracked: Starts and Daily Runtime. These values are historized and are reset daily.
For the purposes of this test, it is assumed the generator is operating correctly. This test will not
verify the operability of the local controls.
2.3.1.2,®¢ « #®³±®«
The generator will operate automatically upon loss of grid power. The Automatic Transfer Switch
(ATS) will switch, allowing power from the generator to feed the system, rather than the grid
power. There is also a weekly test of the generator and ATS.
2.3.1.3 2¤¬®³¤ - ´ « #®³±®«
There is no remote manual control associated with this control strategy.
2.3.1.4 2¤¬®³¤ !´³®¬ ³¨¢ #®³±®«
There is no remote automatic control associated with this control strategy.
2.3.23¯¤¢¨¥¨¢ ³¨® 2¤¥¤±¤¢¤
None.
2.3.3!¯¯«¨¢ ¡«¤ )²³±´¬¤³²
Generator Fuel Low-Level Switch
2.3.4!¯¯«¨¢ ¡«¤ %°´¨¯¬¤³
Lift Station Generator
Automatic Transfer Switch
2.3.53#!$! )³¤±¥ ¢¤
The generator is monitored by the RTU. The RTU in turn sends a signal to the graphic interface
indicating the following statuses for the generator:
Generator Run status.
Automatic Transfer Switch Control Status.
Generator Daily Runtime
Generator Daily Starts
Generator Low Fuel Tank Switch
The tank level is monitored and alarms are generated based on operator’s high- and low-level
alarm setpoints, which are adjustable at the HMI. The status of the low- and high-level float
switches are also monitored.
2.3.6$¤µ¨ ³¨®²
None.
2.3.74¤²³ 0±®¢¤£´±¤² Ȩ²³¤¯ȃ¡¸ȃ²³¤¯ȩ
2.3.7.1 3³ ³´²ȃ '¤¤± ³®±
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the generator is Stopped. When
the generator is stopped, the automatic transfer switch should also be in its
normal operating position.
Verify the generator is Stopped by confirming the color of the symbol is red
on the process screen and equipment pop-up and is Stopped in the field.
Verify the ATS is in its normal position by confirming the color of the symbol
1
is red on the equipment pop-up and is in its normal position in the field.
Note the total runtime and total starts accumulated values.
Lift Station Generator – Accumulated Run Time _________________
Lift Station Generator – Accumulated Starts _________________
4¤²³Ȁ Confirm Running Status/ ATS Status/ Runtime and Accumulated Starts
&¨¤«£ !¢³¨®Ȁ Turn ON the Generator
%·¯¤¢³¤£ 2¤²´«³Ȁ
Verify the generator is Running by confirming the color of the symbol is
green on the process screen and equipment pop-up.
2
Verify the ATS is in its alternate position by confirming the color of the
symbol is green on the equipment pop-up and is in its alternate position in
the field.
The total runtime on the equipment pop-up should increment according to
the time spent running. Total starts accumulated values should increment by
one.
4¤²³ #«¤ ȃ5¯Ȁ Place generator/ ATS in its normal operating condition
following the test, ready to run
&¨¤«£ !¢³¨®Ȁ Turn OFF the Generator
%·¯¤¢³¤£ 2¤²´«³Ȁ
3
Verify the generator is Stopped by confirming the color of the symbol is red
on the process screen and equipment pop-up and is Stopped in the field.
Verify the ATS is in its normal position by confirming the color of the symbol
is red on the equipment pop-up and is in its normal position in the field.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
Test: Set Generator Alarm on
&¨¤«£ !¢³¨®Ȁ Using a jumper at the generator panel, simulate the Generator
alarm ON
4%·¯¤¢³¤£ 2¤²´«³Ȁ
Verify that the Generator alarm is active on the alarm pop-up by a flashing
red and white color on the ȏ'%. !,!2-Ȑ tab. Once the alarm is
acknowledged, it will turn to a static red.
4¤²³ #«¤ ȃ5¯Ȁ Remove Generator Alarm
&¨¤«£ !¢³¨®Ȁ Remove the jumper
5%·¯¤¢³¤£ 2¤²´«³Ȁ
Verify that the Generator Alarm is no longer active on the alarm pop up by a
ȏ'%. !,!2-Ȑ tab. The alarm should now appear grey.
2.3.7.2 4¤²³ 2¤²´«³²
#®¬¬¤³²
4¤²³ ±¤²´«³² ¶¤±¤ ² ³¨²¥ ¢³®±¸ Ȩ ȩ 4¤²³ ±¤²´«³² ¶¤±¤ ´² ³¨²¥ ¢³®±¸ Ȩ ȩ
4¤²³ 7¨³¤²²Ȁ
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2¤³¤²³ 7¨³¤²² (if original test results were unsatisfactory):
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2.4'±®´£ 3³®± ¦¤ 4 ª )«¤³ £ 4± ²¥¤± 6 «µ¤²
2.4.13¯¤¢¨¥¨¢ ³¨® 2¤¥¤±¤¢¤
None.
2.4.2!¯¯«¨¢ ¡«¤ )²³±´¬¤³²
Five Million Gallon (5MG) Ground Storage Tank Inlet Valve
Five Million Gallon Ground Storage Tank to One Million Gallon Ground Storage Tank Transfer Valve
One Million Gallon (1MG) Ground Storage Tank Inlet Valve
2.4.3!¯¯«¨¢ ¡«¤ %°´¨¯¬¤³Ȁ
There is no applicable equipment associated with this control strategy.
2.4.43³± ³¤¦¸ $¤²¢±¨¯³¨®Ȁ
2.4.4.1 Overview
The Five Million Gallon (5MG) Ground Storage Tank and One Million Gallon (1MG) Ground Storage
Tank stores water to provide additional storage capacity for the Lower pressure plane.
There is a discrete valve located near the base of the storage tank for allowing water into the tanks,
which are remotely controlled by the SCADA system. Additionally, there is a discrete valve that
allows for hydraulic balancing of the level in the two tanks.
The valves are hardwired to the RTU. The PLC monitors the status of the valve for display at the
HMI.
The HMI includes an “Inhibit” button for each alarm. The valve has a local HOA handswitch that
allows operators to operate the valve locally.
2.4.4.2,®¢ « #®³±®«
Local Manual Control capability for the valves is available at the local valve actuator. To allow
Manual Control of the valve, the operator may select the valve to local control and press the Open or
Close button at the local actuator.
2.4.4.3 2¤¬®³¤ - ´ « #®³±®«
To allow Remote Manual Control of the valve at the SCADA, the operator must place the valve HOA
switch at the valve local actuator in the “Remote” position, and the valve control mode at the SCADA
graphic interface on the equipment pop-up must show “available for Control”
Once in this position, the operator can open or close the valve from the pop-up window.
2.4.4.4 2¤¬®³¤ !´³®¬ ³¨¢ #®³±®«
There is no remote automatic control associated with this control strategy.
2.4.4.5 Permissives
There are no permissives associated with this control strategy.
2.4.4.6 Interlocks
There are no interlocks associated with this control strategy.
2.4.53#!$! )³¤±¥ ¢¤
The followinghardwired I/O are monitored by the operator from the SCADA interface:
Valve Open Status - DI
Valve Closed Status – DI
Valve Local/ Remote Status - DI
Valve Open Command – DO
Valve Close Command - DO
The followingCalculated Point(s) are available from the SCADA interface:
Valve Position Discrepancy Alarm
Valve Uncommanded Change of State Alarm
The discrepancy timers have a default timer setpoint of 120 seconds.
2.4.6$¤µ¨ ³¨®²
None.
2.4.74¤²³ 0±®¢¤£´±¤² Ȩ²³¤¯ȃ¡¸ȃ²³¤¯ȩ
2.4.7.1,®¢ « - ´ « #®³±®« ȟ &¨µ¤ -¨««¨® ' ««® ȨΘ-'ȩ '±®´£ 3³®± ¦¤ 4 ª )«¤³ 6 «µ¤
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the valve is Open and the local
HOA switch is in ,®¢ «ȁ
Verify the Valve is Open by confirming the color of the symbol is green on
1
the process screen. On the equipment pop-up, the valve should indicate
Opened. The HOA Status indication on the equipment pop-up should read
Local.
4¤²³Ȁ Close the valve manually using local controls
&¨¤«£ !¢³¨®Ȁ From the local valve, press the “Close” button on the local valve
actuator.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from green on the
process screen to yellow on the process screen. Verify the state description
2
transitions from Opened on the process screen to Transition on the
equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition on the process screen to Closed on the equipment pop-up.
4¤²³ #«¤ ȃ5¯Ȁ Open the valve manually using local controls
&¨¤«£ !¢³¨®Ȁ From the local valve, press the “Open” button on the local valve
actuator.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state description
3
transitions from Closed on the process screen to Transition on the
equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition on the process screen to Opened on the equipment pop-up.
Repeat steps 1-3 for the following devices:
One Million Gallon (1MG) Ground Storage Tank Inlet Valve
4
Five Million Gallon Ground Storage Tank to One Million Gallon Ground
Storage Tank Transfer Valve
2.4.7.2 2¤¬®³¤ - ´ « #®³±®« ȟ &¨µ¤ -¨««¨® ' ««® ȨΘ-'ȩ '±®´£ 3³®± ¦¤ 4 ª )«¤³ 6 «µ¤
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the valve is Open and the local
HOA switch is in ,®¢ «ȁ The equipment is assumed to be in Manual mode.
If in simulation, force the Open Limit Switch digital input to /.
7
Verify the Valve is Open by confirming the color of the symbol is green on
the process screen. On the equipment pop-up, the valve should indicate
Opened. The HOA Status indication on the equipment pop-up should read
Local.
4¤²³Ȁ Place the valve in Remote Manual control mode.
&¨¤«£ !¢³¨®Ȁ From the local valve actuator, place the HOA handswitch on the
local valve actuator into “Remote” position.
8
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the state description on the equipment pop-up
transitions from Local on the process screen to Remote.
4¤²³Ȁ Close the valve manually using Remote controls
3¨¬´« ³¤£ !¢³¨®Ȁ From the equipment pop-up, press the “Close” button. In
the RTU, force the Open Limit Switch digital input to OFF. In the RTU, force
the Closed Limit Switch digital input to On.
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Close” button.
9
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from green on the
process screen to yellow on the process screen. Verify the state description
transitions from Opened on the process screen to Transition on the
equipment pop-up.
Verify the valve symbol transitions from yellow on the process screen to red
on the process screen. Verify the state description transitions from
Transition to Closed on the equipment pop-up.
4¤²³ #«¤ ȃ5¯Ȁ Open the valve manually using remote controls
3¨¬´« ³¤£ !¢³¨®Ȁ From the equipment pop-up, press the “Open” button. In
the RTU, force the Open Limit Switch digital input to /. In the RTU, force the
Closed Limit Switch digital input to OFF.
10
&¨¤«£ !¢³¨®Ȁ From the equipment pop-up, press the “Open” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red on the
process screen to yellow on the process screen. Verify the state description
transitions from Closed to Transition on the equipment pop-up.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
Verify the valve symbol transitions from yellow on the process screen to
green on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Repeat steps 1-4 for the following devices:
O One Million Gallon (1MG) Ground Storage Tank Inlet Valve
11
Five Million Gallon Ground Storage Tank to One Million Gallon Ground
Storage Tank Transfer Valve
2.4.7.3$¨²¢±¤¯ ¢¸ 4¤²³¨¦ ȟ &¨µ¤ -¨««¨® ' ««® ȨΘ-'ȩ '±®´£ 3³®± ¦¤ 4 ª )«¤³ 6 «µ¤
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the valve is Open and the local
HOA switch is in 2¤¬®³¤ȁ The equipment is assumed to be in Manual mode.
If in simulation, force the Open Limit Switch digital input to /.
Verify the Valve is Open by confirming the color of the symbol is green on
the process screen. On the equipment pop-up, the valve should indicate
4
Opened. The HOA Status indication on the equipment pop-up should read
Local.
Note the Discrepancy Timer SP value:
Discrepancy Timer SP –__________ _______ seconds
4¤²³Ȁ Verify the discrepancy timer functionality.
3¨¬´« ³¤£ !¢³¨®Ȁ From the equipment pop-up, press the “Close” button. In
the RTU, force the Open Limit Switch digital input to OFF. In the RTU, force
the Closed Limit Switch digital input to On.
&¨¤«£ !¢³¨®Ȁ Set the Discrepancy Timer SP to 15 seconds. From the
equipment pop-up, press the “Close” button.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from green on the
process screen to yellow on the process screen. Verify the state description
5
transitions from Opened to Transition on the equipment pop-up.
Verify the Discrepancy Time remaining in the RTU counts down. Allow for the
Discrepancy Timer to expire in the RTU. From the process screen, equipment
pop-up, and the alarm summary, verify the equipment Discrepancy alarm is
active.
Verify the valve symbol transitions from yellow to red on the process screen.
Verify the state description transitions from Transition to Closed on the
equipment pop-up.
4¤²³Ȁ Restore valve functionality.
&¨¤«£ !¢³¨®Ȁ Acknowledge the alarm. Set the Discrepancy Timer SP to the
6
original setpoint. Click the Fail Reset Command
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the alarms have cleared.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
4¤²³ #«¤ ȃ5¯Ȁ Open the valve manually using remote controls
3¨¬´« ³¤£ !¢³¨®Ȁ From the equipment pop-up, press the “Open” button. In
the RTU, force the Open Limit Switch digital input to /. In the RTU, force the
Closed Limit Switch digital input to OFF.
&¨¤«£ !¢³¨®Ȁ Restore the valve position feedback. Acknowledge the alarms.
From the equipment pop-up, press the “Open” button.
7
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from red to yellow on
the process screen. Verify the state description transitions from Closed to
Transition on the equipment pop-up.
Verify the valve symbol transitions from yellow to green on the process
screen. Verify the state description transitions from Transition to Opened
on the equipment pop-up.
Repeat steps 1-4 for the following devices:
One Million Gallon (1MG) Ground Storage Tank Inlet Valve
8
Five Million Gallon Ground Storage Tank to One Million Gallon Ground
Storage Tank Transfer Valve
2.4.7.4 5¢®¬¬ £¤£ #§ ¦¤ ®¥ 3³ ³¤ 4¤²³¨¦ ȟ &¨µ¤ -¨««¨® ' ««® ȨΘ-'ȩ '±®´£ 3³®± ¦¤
4 ª )«¤³ 6 «µ¤
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ This test procedure assumes the valve is Open and the local
HOA switch is in 2¤¬®³¤ȁ The equipment is assumed to be in Manual mode.
If in simulation, force the Open Limit Switch digital input to /.
4
Verify the Valve is Open by confirming the color of the symbol is green on
the process screen. On the equipment pop-up, the valve should indicate
Opened. The HOA Status indication on the equipment pop-up should read
Local.
4¤²³Ȁ Verify the uncommanded change of state functionality.
3¨¬´« ³¤£ !¢³¨®Ȁ In the RTU, remove the force the Open Limit Switch
digital input to /.
&¨¤«£ !¢³¨®Ȁ Remove the cable terminated into the RTU for the open limit
switch.
5
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from green to yellow
on the process screen. Verify the state description transitions from Opened
to Transition on the equipment pop-up.
From the process scree, equipment pop-up, and the alarm summary, verify
the Uncommanded Change of State alarm is active.
4¤²³ #«¤ ȃ5¯Ȁ Restore valve position feedback functionality.
3¨¬´« ³¤£ !¢³¨®Ȁ In the RTU, force the Open Limit Switch digital input to
On.
&¨¤«£ !¢³¨®Ȁ Restore the open limit switch termination. Acknowledge the
6
alarms. Click the Fail Reset Command.
%·¯¤¢³¤£ 2¤²´«³Ȁ Verify the valve symbol transitions from yellow to green
on the process screen. Verify the state description transitions from
Transition to Opened on the equipment pop-up.
Repeat steps 1-3 for the following devices:
One Million Gallon (1MG) Ground Storage Tank Inlet Valve
7
Five Million Gallon Ground Storage Tank to One Million Gallon Ground
Storage Tank Transfer Valve
2.4.7.5 4¤²³ 2¤²´«³²
#®¬¬¤³²
4¤²³ ±¤²´«³² ¶¤±¤ ² ³¨²¥ ¢³®±¸ Ȩ ȩ 4¤²³ ±¤²´«³² ¶¤±¤ ´² ³¨²¥ ¢³®±¸ Ȩ ȩ
4¤²³ 7¨³¤²²Ȁ
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2¤³¤²³ 7¨³¤²² (if original test results were unsatisfactory):
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2.5&«®¶ -¤³¤± £ 4®³ «¨¹¤±
2.5.13³± ³¤¦¸ $¤²¢±¨¯³¨®Ȁ
2.5.1.1/µ¤±µ¨¤¶
The XXXX Pump Station has a flow meter monitoring and totalizing the flow leaving the station.
The flow meter values are totalized within the SCADApack. There are two sets of values that are
tracked: Daily Totals and Previous Day Totals. These values are historized and are reset daily.
For the purposes of this test, it is assumed the flow meter is operating correctly. This test will not
verify the operability and calibration of the local flow meter.
2.5.1.2,®¢ « #®³±®«
There is no local control associated with this control strategy.
2.5.1.3 2¤¬®³¤ - ´ « #®³±®«
There is no remote manual control associated with this control strategy.
2.5.1.4 2¤¬®³¤ !´³®¬ ³¨¢ #®³±®«
There is no remote automatic control associated with this control strategy.
2.5.23¯¤¢¨¥¨¢ ³¨® 2¤¥¤±¤¢¤
None.
2.5.3!¯¯«¨¢ ¡«¤ )²³±´¬¤³²
Lift Station Effluent Flow Meter
2.5.4!¯¯«¨¢ ¡«¤ %°´¨¯¬¤³
None.
2.5.53#!$! )³¤±¥ ¢¤
The flow is monitored by the RTU. The RTU in turn sends a signal to the graphic interface indicating
the following statuses for the generator:
Current Flow Meter Value
Flow Meter Daily Totalized Flow
Flow Meter Previous Day Totalized Flow
2.5.6$¤µ¨ ³¨®²
None.
2.5.74¤²³ 0±®¢¤£´±¤² Ȩ²³¤¯ȃ¡¸ȃ²³¤¯ȩ
2.5.7.1&«®¶ 4®³ «¨¹¤± ȟ
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
)¨³¨ « 3¤³´¯Ȁ Note the current $ ¨«¸ &«®¶ 4®³ « (MGD) ______________. In the
PLC, set the Flow Rate to 0 (FLOW_RATE=0)
%·¯¤¢³¤£ 2¤²´«³Ȁ
1
Verify the Flow Rate is 0 by confirming the value on the Analog Reading
symbol on the process screen.
4¤²³Ȁ Set the PLC Clock to near Midnight
3¨¬´« ³¤£ !¢³¨®Ȁ Set the PLC time of day to 11:59:55 PM to allow the
midnight flag to be reached and for the $ ¨«¸ &«®¶ 4®³ « to roll over to the
0±¤µ¨®´² $ ¸ &«®¶ 4®³ «.
&¨¤«£ !¢³¨®Ȁ Set the PLC time of day to 11:59:55 PM to allow the midnight
flag to be reached and for the $ ¨«¸ &«®¶ 4®³ « to roll over to the 0±¤µ¨®´²
$ ¸ &«®¶ 4®³ «.
2
%·¯¤¢³¤£ 2¤²´«³Ȁ
When the PLC time reaches 12:00:00 AM, verify the old $ ¨«¸ &«®¶ 4®³ «
(FLOW_TOTAL) is now stored in the 0±¤µ¨®´² $ ¸ &«®¶ 4®³ «
(FLOW_TOTAL_YESTERDAY).
Verify the $ ¨«¸ &«®¶ 4®³ « is reset to 0.
4¤²³Ȁ Set a Constant Flow
3¨¬´« ³¤£ !¢³¨®Ȁ In the PLC, set the Flow Rate to !¸ .´¬¡¤± '±¤ ³¤±
³§ Ώ ͑͑͑͑͑͑͑͑͑͑ (FLOW_RATE= ____________).
&¨¤«£ !¢³¨®Ȁ In the PLC, set the Flow Rate to !¸ .´¬¡¤± '±¤ ³¤± ³§ Ώ
3
__________ (FLOW_RATE= ____________).
%·¯¤¢³¤£ 2¤²´«³Ȁ
Verify the $ ¨«¸ &«®¶ 4®³ « is Increasing. Wait a period before continuing to
the next step to allow more totalization to occur.
3³¤¯ .®ȁ 0±®¢¤£´±¤ 0 ²²¤£
4¤²³Ȁ Calculate the Daily Flow Total
3¨¬´« ³¤£ !¢³¨®Ȁ Calculate the Accumulated Flow Total based on the
following equation:
1440
&¨¤«£ !¢³¨®Ȁ Calculate the Accumulated Flow Total based on the following
equation:
4
1440
%·¯¤¢³¤£ 2¤²´«³Ȁ
Note the ¢ «¢´« ³¤£ $ ¨«¸ &«®¶ 4®³ « (MGAL) ______________.
From the PLC and from the process screen, verify the ¢ «¢´« ³¤£ $ ¨«¸ &«®¶
Total equals the displayed $ ¨«¸ &«®¶ 4®³ « (FLOW_TOTAL).
4¤²³Ȁ Set the PLC Clock to near Midnight
3¨¬´« ³¤£ !¢³¨®Ȁ Set the PLC time of day to 11:59:55 PM to allow the
midnight flag to be reached and for the $ ¨«¸ &«®¶ 4®³ « to roll over to the
0±¤µ¨®´² $ ¸ &«®¶ 4®³ «.
&¨¤«£ !¢³¨®Ȁ Set the PLC time of day to 11:59:55 PM to allow the midnight
flag to be reached and for the $ ¨«¸ &«®¶ 4®³ « to roll over to the 0±¤µ¨®´²
$ ¸ &«®¶ 4®³ «.
5
%·¯¤¢³¤£ 2¤²´«³Ȁ
When the PLC time reaches 12:00:00 AM, verify the old $ ¨«¸ &«®¶ 4®³ «
(FLOW_TOTAL) from 3³¤¯ Γ is now stored in the 0±¤µ¨®´² $ ¸ &«®¶ 4®³ «
(FLOW_TOTAL_YESTERDAY).
Verify the $ ¨«¸ &«®¶ 4®³ « is reset to 0.
2.5.7.2 4¤²³ 2¤²´«³²
#®¬¬¤³²
4¤²³ ±¤²´«³² ¶¤±¤ ² ³¨²¥ ¢³®±¸ Ȩ ȩ 4¤²³ ±¤²´«³² ¶¤±¤ ´² ³¨²¥ ¢³®±¸ Ȩ ȩ
4¤²³ 7¨³¤²²Ȁ
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2¤³¤²³ 7¨³¤²² (if original test results were unsatisfactory):
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2.5.7.3 4¤²³ 2¤²´«³²
#®¬¬¤³²
4¤²³ ±¤²´«³² ¶¤±¤ ² ³¨²¥ ¢³®±¸ Ȩ ȩ 4¤²³ ±¤²´«³² ¶¤±¤ ´² ³¨²¥ ¢³®±¸ Ȩ ȩ
4¤²³ 7¨³¤²²Ȁ
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2¤³¤²³ 7¨³¤²² (if original test results were unsatisfactory):
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2.65²³±´¢³´±¤£ 4¤²³¨¦
There is a difference between structured and unstructured testing. In structured testing, there is a
well-defined test strategy that is adhered to prescriptively. Although both the strategy and the
planning should be flexible, it is not wise to make one big test strategy up front and stick to it. There
will inevitably be test cases that will come up during the course of testing that were not considered
previously. This ad-hoc testing should be captured and recorded as part of the test. For this reason,
allowance is made for recording any ad-hoc unstructured testing that occurs.
2.6.13¯¤¢¨¥¨¢ ³¨® 2¤¥¤±¤¢¤
None.
2.6.2!¯¯«¨¢ ¡«¤ )²³±´¬¤³²
There is no applicable instrumentation associated with this control strategy.
2.6.3!¯¯«¨¢ ¡«¤ %°´¨¯¬¤³Ȁ
There is no applicable equipment associated with this control strategy.
2.6.43³± ³¤¦¸ $¤²¢±¨¯³¨®Ȁ
2.6.4.1 Overview
2.6.4.2,®¢ « #®³±®«
There is no local control associated with this control strategy.
2.6.4.3 2¤¬®³¤ - ´ « #®³±®«
There is no remote manual control associated with this control strategy.
2.6.4.4 2¤¬®³¤ !´³®¬ ³¨¢ #®³±®«
There is no remote automatic control associated with this control strategy.
2.6.4.5 Permissives
There are no permissives associated with this control strategy.
2.6.4.6 Interlocks
There are no interlocks associated with this control strategy.
2.6.53#!$! )³¤±¥ ¢¤
Not defined
2.6.6$¤µ¨ ³¨®²
None.
2.6.74¤²³ 0±®¢¤£´±¤² Ȩ²³¤¯ȃ¡¸ȃ²³¤¯ȩ
2.6.7.1 5²³±´¢³´±¤£ 4¤²³¨¦ ȟ ͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕͕
0 ²²¤£
)³¤¬ 4¤²³ 0±®¢¤£´±¤ %·¯¤¢³¤£ 2¤²´«³²
.®ȁ
Simulated Action:
1
Field Action:
Simulated Action:
2
Field Action:
Simulated Action:
3
Field Action:
2.6.7.2 4¤²³ 2¤²´«³²
#®¬¬¤³²
4¤²³ ±¤²´«³² ¶¤±¤ ² ³¨²¥ ¢³®±¸ Ȩ ȩ 4¤²³ ±¤²´«³² ¶¤±¤ ´² ³¨²¥ ¢³®±¸ Ȩ ȩ
4¤²³ 7¨³¤²²Ȁ
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
2¤³¤²³ 7¨³¤²² (if original test results were unsatisfactory):
___________________________ ___________________________ ____________
Contractor Owner’s Representative Date
PAGE INTENTIONALLY LEFT BLANK
!!
40 61 26 PROCESS CONTROL SYSTEM - TRAINING
1.00GENERAL
1.01SCOPE OF WORK
A.The Process Control System Integrator (PCSI) shall provide all training, training procedures,
training forms, and training coordination with the OWNER/ENGINEER and CONTRACTOR as
specified herein and within Division 40, Section 40 61 00, Process Control and
Instrumentation Systems – General Provisions.
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
B.Refer to Division 40, Section 40 68 00, Applications Engineering Services, for ASP
requirements of the PCSI.
1.03SUBMITTAL REQUIREMENTS
A.General:
1.Refer to Division 01 for general submittal requirements.
2.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
3.Submit electronic Acrobat (PDF) copies of all teaching aids and training manuals upon
completion of training.
4.The PCSI shall prepare and submit a complete overall Process Control System training
plan. The training plan shall include:
a.Definitions, objectives, and target audience of each course:
1)Schedule of training courses included proposed dates, duration, and
locations of each class.
b.A complete copy of all proposed handouts and training materials. Training
information shall be bound and logically arranged with all materials reduced to a
maximum size of 11-inch by 17-inch, then folded to 8.5-inch by 11-inch for
inclusion into the binder.
1.04COORDINATION MEETINGS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.05REFERENCE STANDARDS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
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1.06QUALITY ASSURANCE
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
B.Contractors conducting training shall be qualified, demonstrate experience in the subject
matter requiring training, and be intimately familiar with the operation and control of the
system provided.
C.For equipment and systems beyond the expertise of PCSI staff, training services of a fully
qualified manufacturer representative shall be provided.
1.07DELIVERY, STORAGE, AND HANDLING
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions, project/site requirements.
1.08NOMENCLATURE AND IDENTIFICATION
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.09WARRANTY
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.10PROJECT/SITE REQUIREMENTS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
2.00PRODUCTS (NOT USED)
3.00EXECUTION
3.01GENERAL REQUIREMENTS – TRAINING
A.The training program shall represent a comprehensive program covering all aspects of the
operation and maintenance of the system.
B.All training schedules shall be coordinated with and at the convenience of the OWNER.
Shift training may be required to correspond to the OWNER’s working schedule.
C.All on-site instructors must be intimately familiar with the operation and control of the
OWNER’s facilities.
D.Provide detailed training manuals to supplement the training courses. The manuals shall
include specific details of equipment supplied and operations specific to the project. A print
copy of the manuals shall be provided for each student. Provide electronic copy of each
training manual in PDF format for OWNER’s future use.
E.The trainer shall make use of teaching aids, manuals, slide/video presentations, etc. After
the training services, all training materials shall be delivered to OWNER.
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F.The OWNER reserves the right to videotape all custom training sessions. All training tapes
shall become the sole property of the OWNER.
G.The system supplier shall be retained to provide operation and maintenance training for all
plant monitoring and control system equipment as specified herein.
H.For equipment items not manufactured by the system supplier, on-site training shall be
provided by an authorized representative of the equipment manufacturer. The
manufacturer’s representative shall be fully knowledgeable in the operation and
maintenance of the equipment.
I.All costs associated with the manufacturer’s training sessions, including travel, lodging, car
rental, and meals for the OWNER’s representatives, shall be the responsibility of the PCSI
and shall be included in the contract price. Travel for the OWNER’s representatives shall be
via nonstop flight, originating and terminating at San Antonio International Airport.
3.02TRAINING SUMMARY
A.The following training courses listed in the summary table shall, as a minimum, be
provided:
Quantity Session Number
of Duration Attending a Training
Sessions (Hours) Session Responsibility
1.
On-site Training
a. PCSI/
Field Instruments – Operator 1 4 10
Manufacturer
b. 2 Hours
Control System – Operator
2 for each 10 ASP
Prior to start-up
PLC/OIT
c. 2 Hours
Control System – Operator
2 for each 10 ASP
After start-up
PLC/OIT
3.03ON-SITE TRAINING
A.On-Site Training - Programmable Logic Controller (PLC) Hardware and Software, and OIT
Software:
1.Provide manufacturer’s standard training course for the OWNER’s personnel in the
operation, configuration, programming, installation, and maintenance of the PLC
hardware and software, and OIT software supplied.
2.Training shall consist of classroom and hands-on instruction utilizing the Owner’s
system.
3.Detailed training shall be provided on the actual configuration and implementation for
this Contract. Training shall cover all aspects of the system that will allow the Owner’s
personnel to maintain, modify, troubleshoot, and develop future additions/deletions
to the system. The training shall cover the following subjects, as a minimum:
a.System overview
b.System hardware components and specific equipment arrangements
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c.System startup, shut down, load, backup, and historical archival/retrieval
procedures
d.Specific application configuration covering the overall design and implementation
of the applications provided under this Contract. The intent is to make the
student fully knowledgeable in all aspects of the system provided.
e.Periodic maintenance
f.Troubleshooting and diagnosis
g.Network configuration, communications, and operation
4.Control System Training – Operator Prior to start-up
a.This training shall be held before the FDT, but not more than one month before
the FDT.
B.On-Site Training - Field Instruments
1.Manufacturer instrument training shall be provided for the new instruments provided
by PCSI.
2.The instrument manufacturer or manufacturer’s certified service representative shall
provide start-up and training services for the level Sensor/Transmitter/Controller. This
work shall not be done by the PCSI/ASP CONTRACTOR.
3.Provide hardware training and instruction on the maintenance of the field
instrumentation for the OWNER’s instrumentation technicians. This training shall be
conducted before the Functional Demonstration Test, but no more than one month
before and at a time suitable to the OWNER. This training shall take place at the
OWNER’s facility. As a minimum, the following shall be included:
a.Training in standard hardware maintenance for the instruments provided.
b.Specific training for the actual instrumentation configuration to provide a detailed
understanding of how the equipment and components are arranged, connected,
and set up for this Contract.
c.Test, adjustment, and calibration procedures.
d.Troubleshooting and diagnosis.
e.Periodic maintenance.
C.For training session requirements for PCSI-provided Application System Programming
(ASP), refer to Division 40, Section 40 68 00, Applications Engineering Services.
END OF SECTION
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40 61 93 PROCESS CONTROL SYSTEM - INPUT/OUTPUT LIST
1.00GENERAL
1.01SCOPE OF WORK
A.This Section includes the Process Control System (PCS) Input/Output (I/O) List for each
controller. The Lists are intended to reflect the signals that serve as the basis of the
application to be programmed by the PCSI and ASP, who is furnishing the process
monitoring and control functionality specified within this Division.
B.Existing PLC programs and I/O list will be made available to the PCSI/ASP upon request.
C.Existing HMI I/O list will be made available to the PCSI/ASP upon request.
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.Refer to Division 40, Section 40 68 00, Process Control System – Applications Services, for
programming requirements of the PCSI.
C.Refer to Division 40, Section 40 61 96, Process Control System – Control Descriptions.
1.03SUBMITTALS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions, for
submittal requirements.
B.Refer to Division 40, Section 40 68 00, Process Control System – Applications Services.
1.04SYSTEM DESCRIPTION
A.The PCS I/O List provides the minimum physical signal requirements of the control loops
represented in the Contract Documents. Provide additional soft signals as required to fully
implement the functionality described in these specifications.
B.The PCS I/O List is not intended to be an inclusive listing of all elements and appurtenances
required to execute the loop functions. It is intended to supplement and complement the
Drawings and other Specification Sections. The design I/O List shall not be considered equal
to the exact field wired I/O.
C.The PCS I/O List does not show all hardware and software necessary to perform all control
functions specified herein and as shown on Drawings. PCSI to provide all hardware and
software necessary to provide a complete and working system.
D.The attached I/O list for the new PLC inputs/outputs includes the following information:
1.P&ID: Reference drawing for the input/output.
2.PLC: The PLC name that input/output is connected to.
3.I/O TYPE: The identifier of the type of point
a.Analog In (AI), Analog Output (AO), Discrete Input (DI) or Discrete Output (DO).
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4.TAG NUMBER: The identifier assigned to a device or variable that performs a function
in the control system. Tag numbering shall follow the Owner Tag Naming Standards.
5.DESCRIPTION: A description of the function of the device or variable (text that includes
signal source, control function, etc.).
6.ENGINEERING RANGE/STATE: The range in engineering units corresponding to an
analog 4-20 mA signal or scalable variable (LO/HI), or the text description
corresponding to each state of a discrete point (ON/OFF).
7.ENGINEERING UNITS (EU): The engineering units associated with the Analog I/O or
scalable variable.
8.ALARM INFORMATION:
a.ALARM/EVENT: Designation of the data point as an Alarm or an Event.
b.HI HI: Assignment of the High-High alarm limit. (If applicable)
c.HI: Assignment of the High alarm limit. (If applicable)
d.LO: Assignment of the Low alarm limit. (If applicable)
e.LO LO: Assignment of the Low - Low alarm limit. (If applicable)
9.HISTORICAL INFORMATION:
a.UPDATE RATE: Rate at which a historically collected data point is to be collected
by the historian.
b.HISTORICAL LOGGING: Designation if the data point is to be historically collected.
The actual points to be placed into the Historian will be finalized in coordination
with the Owner.
1.05INPUT/OUTPUT LIST
A.The PCS I/O lists for the new PLC input/outputs are based on the Drawings and included
within the tables attached within this Section. The PCS programmer shall follow standards
to complete the I/O List submittal for the Engineer and Owner during construction.
1.06INPUT/OUTPUT LIST SUMMARY
A.The following is a summary of the PLCs inputs and outputs:
1.Resaca Lift Station PLC
a.PLC Analog Inputs - 16
b.PLC Analog Outputs - 8
c.PLC Discrete Inputs - 26
d.PLC Discrete Outputs - 3
2.Generator PLC (ATS/GEN:OSO)
a.PLC Discrete Inputs - 24
b.PLC Discrete Outputs – 16
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3.Master Blower PLC
a.PLC Analog Inputs - 14
b.PLC Analog Outputs - 4
c.PLC Discrete Inputs - 16
d.PLC Discrete Outputs - 1
4.Blower 1,2,3,4 PLC
a.PLC Analog Inputs - 6
b.PLC Analog Outputs - 1
c.PLC Discrete Inputs - 5
d.PLC Discrete Outputs - 3
2.00PRODUCTS (NOT USED)
3.00EXECUTION (NOT USED)
ATTACHMENTS:
40 61 93A Attachment A – Input/Output List
END OF SECTION
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SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
04-I-01RMPRESCDIBRD_RWW_LSH4001_LHRESACA LS WEST WETWELL HIGH LEVELALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_LIT4001_LIRESACA LS WEST WETWELL LEVEL200FEETALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_LSL4001_LLRESACA LS WEST WETWELL LOW LEVELNORMALALARMN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_LSH4004_LHRESACA LS EAST WETWELL HIGH LEVELALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_LIT4004_LIRESACA LS EAST WETWELL LEVEL200FEETALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_LSL4004_LLRESACA LS EAST WETWELL LOW LEVELNORMALALARMN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4001_YHRESACA LS PUMP 1 AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4001_YLRESACA LS PUMP 1 MANUALMANUALAUTON/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4001_MSHRESACA LS PUMP 1 RUN STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4001_XRESACA LS PUMP 1 DRIVE FAILUREFAILNORMALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4001_MSLRESACA LS PUMP 1 OFF STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDOBRD_RWW_PMP4001_MCHRESACA LS PUMP 1 START COMMANDSTARTN/AN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCAOBRD_RWW_PMP4001_SSRESACA LS PUMP 1 SPEED SETPOINT1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_PMP4001_SIRESACA LS PUMP 1 SPEED FEEDBACK1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4002_YHRESACA LS PUMP 2 AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4002_YLRESACA LS PUMP 2 MANUALMANUALAUTON/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4002_MSHRESACA LS PUMP 2 RUN STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4002_XRESACA LS PUMP 2 DRIVE FAILUREFAILNORMALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4002_MSLRESACA LS PUMP 2 OFF STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDOBRD_RWW_PMP4002_MCHRESACA LS PUMP 2 START COMMANDSTARTN/AN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCAOBRD_RWW_PMP4002_SSRESACA LS PUMP 2 SPEED SETPOINT1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_PMP4002_SIRESACA LS PUMP 2 SPEED FEEDBACK1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4003_YHRESACA LS PUMP 3 AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4003_YLRESACA LS PUMP 3 MANUALMANUALAUTON/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4003_MSHRESACA LS PUMP 3 RUN STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4003_XRESACA LS PUMP 3 DRIVE FAILUREFAILNORMALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4003_MSLRESACA LS PUMP 3 OFF STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDOBRD_RWW_PMP4003_MCHRESACA LS PUMP 3 START COMMANDSTARTN/AN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCAOBRD_RWW_PMP4003_SSRESACA LS PUMP 3 SPEED SETPOINT1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_PMP4003_SIRESACA LS PUMP 3 SPEED FEEDBACK1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4004_YHRESACA LS PUMP 4 AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4004_YLRESACA LS PUMP 4 MANUALMANUALAUTON/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4004_MSHRESACA LS PUMP 4 RUN STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4004_XRESACA LS PUMP 4 DRIVE FAILUREFAILNORMALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4004_MSLRESACA LS PUMP 4 OFF STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDOBRD_RWW_PMP4004_MCHRESACA LS PUMP 4 START COMMANDSTARTN/AN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCAOBRD_RWW_PMP4004_SSRESACA LS PUMP 4 SPEED SETPOINT1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_PMP4004_SIRESACA LS PUMP 4 SPEED FEEDBACK1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4005_YHRESACA LS PUMP 5 AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4005_YLRESACA LS PUMP 5 MANUALMANUALAUTON/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4005_MSHRESACA LS PUMP 5 RUN STATUSRUNNINGOFFN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4005_XRESACA LS PUMP 5 DRIVE FAILUREFAILNORMALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4005_MSLRESACA LS PUMP 5 OFF STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDOBRD_RWW_PMP4005_MCHRESACA LS PUMP 5 START COMMANDSTARTN/AN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCAOBRD_RWW_PMP4005_SSRESACA LS PUMP 5 SPEED SETPOINT1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_PMP4005_SIRESACA LS PUMP 5 SPEED FEEDBACK1000%ALARMN/AN/AN/AN/AN/A
Page 1 of 9
Process Control System - Input/Output List
40 61 93A Process Control System - InputOutput List - Attachment A
KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
04-I-01RMPRESCDIBRD_RWW_PMP4006_YHRESACA LS PUMP 6 AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4006_YLRESACA LS PUMP 6 MANUALMANUALAUTON/AEVENTN/AN/AN/AN/AN/A
Page 2 of 9
Process Control System - Input/Output List
40 61 93A Process Control System - InputOutput List - Attachment A
KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
04-I-01RMPRESCDIBRD_RWW_PMP4006_MSHRESACA LS PUMP 6 RUN STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4006_XRESACA LS PUMP 6 DRIVE FAILUREFAILNORMALN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_PMP4006_MSLRESACA LS PUMP 6 OFF STATUSOFFRUNNINGN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCDOBRD_RWW_PMP4006_MCHRESACA LS PUMP 6 START COMMANDSTARTN/AN/AEVENTN/AN/AN/AN/AN/A
04-I-01RMPRESCAOBRD_RWW_PMP4006_SSRESACA LS PUMP 6 SPEED SETPOINT1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCAIBRD_RWW_PMP4006_SIRESACA LS PUMP 6 SPEED FEEDBACK1000%ALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_LSH4010_LHVALVE VAULT HIGH LEVELALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_XGENERATOR COMMON ALARMALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_MXGENERATOR FAIL STARTALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_JX1GENERATOR LOAD SHED ALARMALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_LLGENERATOR LOW FUEL ALARMALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_JX2GENERATOR VOLTAGE FREQUENCY ALARMALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_JX3GENERATOR WEAK BATTERYALARMNORMALN/AALARMN/AN/AN/AN/AN/A
04-I-01RMPRESCDIBRD_RWW_GEN4100_MSLGENERATOR SHUT DOWNSHUT DOWNNORMALN/AALARMN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01DIBRD_AIR_FLT01_PHINLET FILTER HIGH PRESSUREALARMNORMALN/AALARMN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01DIBRD_AIR_VCP01_JX2DC POWER FAILURE 1FAILNORMALN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01DIBRD_AIR_VCP01_JX3DC POWER FAILURE 2FAILNORMALN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM50_YRBASIN 1 AIR CONTROL VALVE REMOTEREMOTELOCALN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM60_YRBASIN 2 AIR CONTROL VALVE REMOTEREMOTELOCALN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM70_YRBASIN 3 AIR CONTROL VALVE REMOTEREMOTELOCALN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM80_YRBASIN 4 AIR CONTROL VALVE REMOTEREMOTELOCALN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01DIBRD_AIR_VCP01_JX1AC POWER STATUSONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01DIBRD_AIR_VCP01_UPSUPS STATUSONOFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM50_ZSHBASIN 1 AIR CONTROL VALVE FULL OPENOPEN OFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM50_ZSLBASIN 1 AIR CONTROL VALVE FULL CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM60_ZSHBASIN 2 AIR CONTROL VALVE FULL OPENOPEN OFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM60_ZSLBASIN 2 AIR CONTROL VALVE FULL CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM70_ZSHBASIN 3 AIR CONTROL VALVE FULL OPENOPEN OFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM70_ZSLBASIN 3 AIR CONTROL VALVE FULL CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM80_ZSHBASIN 4 AIR CONTROL VALVE FULL OPENOPEN OFFN/AEVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01DIBRD_AIR_EAM80_ZSLBASIN 4 AIR CONTROL VALVE FULL CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01DOBRD_AIR_VCP01_AXALARM LAMP OUTONOFFN/AALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_AIT15_AIBASIN 1 DISSOLVED OXYGENTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_AIT25_AIBASIN 2 DISSOLVED OXYGENTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_AIT35_AIBASIN 3 DISSOLVED OXYGENTBDTBDALARMN/A N/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_AIT45_AIBASIN 4 DISSOLVED OXYGENTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_FIT50_FIBASIN 1 AIR FLOWTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_FIT60_FIBASIN 2 AIR FLOWTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_FIT70_FIBASIN 3 AIR FLOWTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_FIT80_FIBASIN 4 AIR FLOWTBDTBDALARMN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_EAM50_ZIBASIN 1 AIR CONTROL VALVE POSITION1000%EVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_EAM60_ZIBASIN 2AIR CONTROL VALVE POSITION1000%EVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_EAM70_ZIBASIN 3 AIR CONTROL VALVE POSITION1000%EVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AIBRD_AIR_EAM80_ZIBASIN 4 AIR CONTROL VALVE POSITION1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01AIBRD_AIR_TIT01_TIAIR INTAKE TEMPERATURETBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP01AIBRD_AIR_PIT20_PIHEADER PRESSURE RAW INTBDTBDEVENTN/AN/AN/AN/AN/A
Page 3 of 9
Process Control System - Input/Output List
40 61 93A Process Control System - InputOutput List - Attachment A
KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
21-I-01BRD-AIR-VCP01AOBRD_AIR_EAM50_ZCBASIN 1 AIR CONTROL VALVE POSITION SETPOINT1000%EVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AOBRD_AIR_EAM60_ZCBASIN 2 AIR CONTROL VALVE POSITION SETPOINT1000%EVENTN/AN/AN/AN/AN/A
Page 4 of 9
Process Control System - Input/Output List
40 61 93A Process Control System - InputOutput List - Attachment A
KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
21-I-01BRD-AIR-VCP01AOBRD_AIR_EAM70_ZCBASIN 3 AIR CONTROL VALVE POSITION SETPOINT1000%EVENTN/AN/AN/AN/AN/A
21-I-01BRD-AIR-VCP01AOBRD_AIR_EAM80_ZCBASIN 4 AIR CONTROL VALVE POSITION SETPOINT1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DIBRD_AIR_BLO11_MSHBLOWER 1 RUN STATUS RAWRUNNINGOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DIBRD_AIR_VCP11_JX2BLOWER 1 PLC 24V POWER SUPPLY 1 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DIBRD_AIR_VCP11_JX3BLOWER 1 PLC 24V POWER SUPPLY 2 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DIBRD_AIR_VCP11_YRBLOWER 1 HOA IN AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DIBRD_AIR_VCP11_UPSBLOWER 1 UPS STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DIBRD_AIR_VCP11_JX1BLOWER 1 AC POWER STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-AIR-VCP11DOBRD_AIR_BLO11_SSBLOWER 1 RUN RELAYSTARTSTOPN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DOBRD_AIR_VCP11_AXBLOWER 1 ALARM LIGHTONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11DOBRD_AIR_BVL11_ZCHBLOWER 1 BLOWOFF VALVE OPEN/CLOSE RELAYOPENCLOSEDN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_IIBLOWER 1 CURRENT TBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_TI1BLOWER 1 INBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_TI2BLOWER 1 OUTBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_AI1BLOWER 1 INBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_AI2BLOWER 1 OUTBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_VAL11_ZIBLOWER 1 INLET VALVE POSITION ACTUAL RAW1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AOBRD_AIR_VAL11_ZCBLOWER 1 INLET VALVE OUT1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_JI1BLOWER 1 POWER ATBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_JI2BLOWER 1 POWER BTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP11AIBRD_AIR_BLO11_JI3BLOWER 1 POWER CTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DIBRD_AIR_BLO12_MSHBLOWER 2 RUN STATUS RAWRUNNINGOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DIBRD_AIR_VCP12_JX2BLOWER 2 PLC 24V POWER SUPPLY 1 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DIBRD_AIR_VCP12_JX3BLOWER 2 PLC 24V POWER SUPPLY 2 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DIBRD_AIR_VCP12_YRBLOWER 2 HOA IN AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DIBRD_AIR_VCP12_UPSBLOWER 2 UPS STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DIBRD_AIR_VCP12_JX1BLOWER 2 AC POWER STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-AIR-VCP12DOBRD_AIR_BLO12_SSBLOWER 2 RUN RELAYSTARTSTOPN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DOBRD_AIR_VCP12_AXBLOWER 2 ALARM LIGHTONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12DOBRD_AIR_BVL12_ZCHBLOWER 2 BLOWOFF VALVE OPEN/CLOSE RELAYOPENCLOSEDN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_IIBLOWER 2 CURRENT TBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_TI1BLOWER 2 INBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_TI2BLOWER 2 OUTBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_AI1BLOWER 2 INBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_AI2BLOWER 2 OUTBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_VAL12_ZIBLOWER 2 INLET VALVE POSITION ACTUAL RAW1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AOBRD_AIR_VAL12_ZCBLOWER 2 INLET VALVE OUT1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_JI1BLOWER 2 POWER ATBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_JI2BLOWER 2 POWER BTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP12AIBRD_AIR_BLO12_JI3BLOWER 2 POWER CTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DIBRD_AIR_BLO13_MSHBLOWER 3 RUN STATUS RAWRUNNINGOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DIBRD_AIR_VCP13_JX2BLOWER 3 PLC 24V POWER SUPPLY 1 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DIBRD_AIR_VCP13_JX3BLOWER 3 PLC 24V POWER SUPPLY 2 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DIBRD_AIR_VCP13_YRBLOWER 3 HOA IN AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DIBRD_AIR_VCP13_UPSBLOWER 3 UPS STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DIBRD_AIR_VCP13_JX1BLOWER 3 AC POWER STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
Page 5 of 9
Process Control System - Input/Output List
40 61 93A Process Control System - InputOutput List - Attachment A
KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
22-I-02BRD-AIR-VCP13DOBRD_AIR_BLO13_SSBLOWER 3 RUN RELAYSTARTSTOPN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13DOBRD_AIR_VCP13_AXBLOWER 3 ALARM LIGHTONOFFN/AEVENTN/AN/AN/AN/AN/A
Page 6 of 9
Process Control System - Input/Output List
40 61 93A Process Control System - InputOutput List - Attachment A
KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
22-I-01BRD-AIR-VCP13DOBRD_AIR_BVL13_ZCHBLOWER 3 BLOWOFF VALVE OPEN/CLOSE RELAYOPENCLOSEDN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_IIBLOWER 3 CURRENT TBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_TI1BLOWER 3 INBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_TI2BLOWER 3 OUTBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_AI1BLOWER 3 INBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_AI2BLOWER 3 OUTBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_VAL13_ZIBLOWER 3 INLET VALVE POSITION ACTUAL RAW1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AOBRD_AIR_VAL13_ZCBLOWER 3 INLET VALVE OUT1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_JI1BLOWER 3 POWER ATBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_JI2BLOWER 3 POWER BTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP13AIBRD_AIR_BLO13_JI3BLOWER 3 POWER CTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DIBRD_AIR_BLO14_MSHBLOWER 4 RUN STATUS RAWRUNNINGOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DIBRD_AIR_VCP14_JX2BLOWER 4 PLC 24V POWER SUPPLY 1 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DIBRD_AIR_VCP14_JX3BLOWER 4 PLC 24V POWER SUPPLY 2 STATUS ONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DIBRD_AIR_VCP14_YRBLOWER 4 HOA IN AUTOAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DIBRD_AIR_VCP14_UPSBLOWER 4 UPS STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DIBRD_AIR_VCP14_JX1BLOWER 4 AC POWER STATUS INONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-AIR-VCP14DOBRD_AIR_BLO14_SSBLOWER 4 RUN RELAYSTARTSTOPN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DOBRD_AIR_VCP14_AXBLOWER 4 ALARM LIGHTONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14DOBRD_AIR_BVL14_ZCHBLOWER 4 BLOWOFF VALVE OPEN/CLOSE RELAYOPENCLOSEDN/AEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_IIBLOWER 4 CURRENT TBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_TI1BLOWER 4 INBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_TI2BLOWER 4 OUTBOARD BEARING TEMPERATURE RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_AI1BLOWER 4 INBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_AI2BLOWER 4 OUTBOARD BEARING VIBRATIONS RAWTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_VAL14_ZIBLOWER 4 INLET VALVE POSITION ACTUAL RAW1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AOBRD_AIR_VAL14_ZCBLOWER 4 INLET VALVE OUT1000%EVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_JI1BLOWER 4 POWER ATBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_JI2BLOWER 4 POWER BTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-01BRD-AIR-VCP14AIBRD_AIR_BLO14_JI3BLOWER 4 POWER CTBDTBDEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_MBR_ZSLMAIN BREAKER CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_MBR_ZSOMAIN BREAKER OPENOPENOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_MBR_X2MAIN BREAKER TOC ALARMONOFFN/AALARMN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_MBR_X3MAIN BREAKER LOCKOUTLOCKOUTNORMALN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_MBR_ZCLMAIN BREAKER CLOSECLOSE N/AN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_MBR_X1MAIN BREAKER TRIPONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_MBR_ZMCMAIN SYNCHTBDTBDN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_MBR_ZMMAIN SYNCTBDTBDN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_UTL_ESLMAIN UNDERVOLTAGEUNDERVOLTAGENORMALN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_UTL_ESHMAIN VOLTAGE AVAILABLEAVAILABLE NOT AVAILABLEN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_ATS_JSHMAIN CONTROL POWERONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_GBR_ZSLGENERATOR BREAKER CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_GBR_ZSHGENERATOR BREAKER OPENOPENOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_GBR_ZCLGENERATOR BREAKER CLOSE CLOSE N/AN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_GBR_X1GENERATOR BREAKER TRIPONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_GBR_X3GENERATOR BREAKER LOCKOUTLOCKOUTNORMALN/AEVENTN/AN/AN/AN/AN/A
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SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
22-I-02BRD-GEN-MBRDIBRD_GEN_GEN_JSHGENERATOR CONTROL POWERONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_GEN_YRGENERATOR AUTO STATUSAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
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Process Control System - Input/Output List
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KVMZ!3134
SECTION 40 61 93A
ATTACHMENT A - INPUT/OUTPUT LIST
HIGH
Alarm InformationHistorical Info
OnOff
IO
P&IDPLCTag No.DescriptionEUNote
Type
EU Range
Alarm/ Update Historical
HI HIHILOWLO LO
EventRate (sec)Logging
HiLo
22-I-02BRD-GEN-MBRDIBRD_GEN_GBR_X2GENERATOR TOC ALARMONOFFN/AALARMN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_GEN_YCHGENERATOR AUTO TRANSFER READYREADYN/AN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_GEN_EMGENERATOR VOLTAGE AVAILABLEAVAILABLE NOT AVAILABLEN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_GEN_YCLGENERATOR AUTO TRANSFER DISABLEDDISABLEDN/AN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_GEN_SSGENERATOR START/STOPSTARTSTOPN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_GEN_IEMGENERATOR OVERVOLTAGE/OVERFREQUENCY CLOSE PERMISSIVEENABLEDISABLEN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_TBR_X2TIE TOC ALARMONOFFN/AALARMN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_TBR_ZSLTIE BREAKER CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_TBR_JSHTIE CONTROL POWERONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_UBR_ZSLFEEDER BREAKER CLOSEDCLOSEDOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_UBR_ZCLFEEDER BREAKER CLOSE CLOSE N/AN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_UBR_X1FEEDER BREAKER TRIPONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_ATS_YRHAUTO MODEAUTONOT AUTON/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_ATS_YRLMANUAL MODEMANUALNOT MANUALN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_ATS_YRMAUTO TRANSFERAUTOMANUALN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_ATS_YLIMANUAL LED INDICATORONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_ATS_YHIAUTO MODE READY LED INDICATORONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_ATS_YXIAUTO TRANSFER DISABLED/FAILEDFAILUREN/AN/AALARMN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDOBRD_GEN_ATS_MSHPLC ONLINEONOFFN/AEVENTN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_ATS_JX124V POWER SUPPLY FAILUREFAILUREOFFN/AALARMN/AN/AN/AN/AN/A
22-I-02BRD-GEN-MBRDIBRD_GEN_ATS_JX224V POWER SUPPLY FAILUREFAILUREOFFN/AALARMN/AN/AN/AN/AN/A
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40 61 96 PROCESS CONTROL SYSTEM - CONTROL DESCRIPTIONS
1.00GENERAL
1.01SCOPE OF WORK
A.This Specification section provides detailed control loop descriptions for the programming
of the Process Control System by the Applications System Programmer (ASP).
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.Refer to Division 40, Section 40 68 00, Applications Engineering Services, for requirements
of ASP.
1.03SUBMITTAL REQUIREMENTS
A.General:
1.Refer to Division 01 for general submittal requirements.
2.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.04COORDINATION MEETINGS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.05REFERENCE STANDARDS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.06QUALITY ASSURANCE
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.07DELIVERY, STORAGE, AND HANDLING
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.08NOMENCLATURE AND IDENTIFICATION
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.09WARRANTY
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.10PROJECT/SITE REQUIREMENTS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
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2.00PRODUCTS (NOT USED)
3.00EXECUTION
3.01GENERAL
A.The following loop descriptions are broken into areas. The following is a list of associated
process areas.
1.Odor Control
2.Septage Hauling
3.Resaca Lift Station
4.Generator 1 and 2
5.Aeration Blowers
6.Aeration Basins
7.Generator
B.The loop descriptions are broken into a hierarchical layer concept. There may be one layer
or multiple layers per loop, depending upon that loop. An example of a multiple layered
loop is as follows:
1.Local: The lowest layer of control, local control, is at that piece of equipment or that
piece of equipment’s panel or drive.
2.The second layer of control is at an intermediate control panel between the
equipment and the process controller I/O card.
3.The third layer would be at the vendor’s PLC or operator interface terminal (OIT).
(Note: An OIT is considered a Remote Control device even if it is physically installed
with the vendor PLC.)
4.The highest layer of control is at the Plant Control System’s process controller (PLC)
with its associated HMI in the main control room, remote office locations, and local or
satellite location OITs.
a.Remote Manual – The Operator issues direct control to devices through the Plant
HMI or the OIT via the PLC (Position Based).
b.Remote Auto – The Operator enters a process setpoint and the PLC actively
controls the equipment to achieve that setpoint (Process Based).
3.02CONTROL FUNCTION DEFINITIONS AND GENERAL CRITERIA
A.The following control loop narratives shall be used in conjunction with all project drawings.
Logic control descriptions and functional diagrams are provided for the HMI, OIT and PLC
software required under this Contract.
B.All alarm and control setpoints shall be adjustable by the Operator at the HMI unless
specifically stated otherwise, even if not shown on the Drawings. These setpoints shall be
password protected to allow access by only the Operators who are given clearance by the
Owner.
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C.Preclusion logic shall be added to all applicable alarms. This logic will prevent secondary
alarms that are a direct result of a primary alarm from being annunciated. For example,
station power failure should not cause a circuit breaker-tripped alarm to be annunciated.
D.All software adjustable alarm setpoints accessible from the HMI shall have adjustable
deadbands unless specifically noted otherwise.
E.Plant personnel must acknowledge all alarms before they can be cleared. No alarm shall
clear automatically until it has been acknowledged.
F.Command Fault (Discrepancy) and Failure Alarms:
1.For all controlled devices such as pumps, valves, etc., if the device is commanded to
Start or Stop (or Open or Close) by the PLC and the device feedback state does not
match the commanded state within a pre-set time, a Command Fault Alarm is
generated by the PLC for display and alarming at the HMI (valves shall remain in the
last state).
2.If a duty pump, or system, is commanded to start and does not start within the pre-set
time, an alarm shall be generated by the PLC for display and alarming at the HMI and
the standby pump shall start without operator intervention.
3.If a device feedback state does not match the commanded state at any time, excluding
the change of state described above, an Uncommanded Change of State Alarm is
generated by the PLC for display and alarming at the HMI (valves shall remain in the
last state).
4.After a Command Fault Alarm occurs, the device cannot be started again until the
Operator at the HMI has issued a Reset. All controlled devices with feedback shall
generate Failure alarms at the PLC for display and alarming at the associated process
graphic displays, even if not shown on the Drawings.
G.Analog Alarms:
1.All analog alarms shall be generated at the HMI level as follows, with the exceptions of
bad value processing and deviation alarms. If the analog point’s value exceeds or drops
below the alarm limit value and set time delay has been passed, then an alarm shall be
generated at the HMI for display and alarming. To eliminate excessive alarm reporting,
the analog point shall remain in alarm until the analog point’s value returns beyond
the limit set by the analog limit deadband.
2.All process analog inputs are displayed, historically collected, and trended. Low-low,
low, high, and high-high alarms shall be calculated at the HMI for display and alarming.
Nuisance alarms, such as low turbidity, shall be inhibited. When a valve is closed or a
pump is not running, the analog flow signal associated with that valve or pump shall
not generate a low flow alarm, and it shall be forced to a zero value.
3.Manual Override:
a.This capability is implemented within the PLC controller. Since scaling is processed
at the controller, the manual override value (operator entered at the HMI) will be
in engineering units, not raw counts. When a point is placed in manual override
mode, the point’s associated data quality is forced to be “Good” as well. Providing
this capability in the controller allows the rest of the logic to operate in the
manual override mode.
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4.Data Quality:
a.A key attribute of every analog input is its associated data quality. This is a simple
Boolean value that indicates whether the analog reading can be trusted. The
value is reset when the value is good, and it is set when it is bad. There are
several checks done on the value before it is declared as “Good.”
5.Bad Value Processing:
a.If the value is not in Manual Override, then the raw value needs to be processed
further before it is converted into its engineering units. The first check is to make
sure the raw reading is within the limits of the instrument. These limits are
specified on an individual point basis. Normally, the limits need to check over or
under-range (open-loop) values, such as the raw count readings for 3-21mA on a
4-20mA instrument. Depending upon the process being monitored, it may require
the range to be narrowed further. For example, a temperature instrument may
have a range from 0 degrees F to 200 degrees F. If the process being measured is
water temperature, then the readings should never get outside 40 degrees F to
100 degrees F. By specifying this set of limits, any reading outside this range
would indicate an instrument problem. If the raw reading is outside these limits,
the point’s data quality would be set to “Bad.” The controller will not maintain
the last good reading; values will be presented as processed by the controller.
6.Deviation Alarms:
a.For all variable speed pumps, if the pump is commanded to run at a specific speed
and the speed feedback signal deviates from the commanded speed by a pre-set
deadband for a pre-set time period, a Speed Deviation alarm is generated by the
PLC for display and alarming at the HMI.
b.For all modulating valves, if the valve is commanded to a specific position, and the
position feedback signal deviates from the requested position by a pre-set
deadband for a pre-set time period, a Position Deviation alarm is generated by
the PLC for display and alarming at the HMI.
c.For all controlled setpoints (i.e., level, flow, etc.), if a process is requested to a
specific setpoint, and the control variable feedback signal deviates from the
requested setpoint by a pre-set deadband for a pre-set time period, a Setpoint
Deviation alarm is generated by the PLC for display and alarming at the HMI.
H.Equipment Runtime and Starts:
1.In an effort to support routine maintenance functions, all motorized equipment
(pumps, motors, motorized gates, etc.) will have their runtime and number of starts
monitored. Unless specified otherwise, the runtime will be monitored in tenths of an
hour increment (every six minutes). Both the runtime and number of starts will
continue to be collected until reset by an operator. When reset, both values will be set
to zero, and the date/time when it was reset will be noted.
2.Two runtime parameters shall be provided for equipment:
a.Accumulated Runtime – Accumulates for the life of the equipment.
b.Resettable Runtime – Runtime with reset capabilities.
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3.See Volume 4 - RUNTIME - Accumulate Runtime and Starts for information on
retaining stored runtime data.
I.Equipment Out Of Service tag (OOS) Command:
1.All controllable equipment is provided with the ability to have an operational tag
applied to it. Upon receiving an Out Of Service tag command from the Operator, the
control logic will inhibit all remote controls of the equipment.
J.Flow Totalization:
1.Every reading that monitors the flow of the main water flow needs to be totalized
daily. Only values with a good value status are totalized. Flow rates and flow totals
shall be indicated and recorded at the HMI. When a valve is closed or a pump is not
running, the flow totalizer shall not accumulate values caused by noise or errors in
calibration.
2.The running total starts at the beginning of the day and totalizes the volume
throughout the day. At the end of the day, it resets that total and starts over. Before
the total is reset, it is stored for examination throughout the next day. Therefore, the
flow total consists of two values: previous day’s total and the total for this day since
midnight. For example: The total reading is calculated by integrating the minutely
average of the MGD readings every minute. The minutely average need to be scaled to
millions of gallons per minute before it is totalized.
While MGD units are used in this example, flow totalization may be for other volumetric flow units
such as gallons per minute (GPM), standard cubic feet per minute (SCFM), etc. ASP shall provide
flow totalization in the base units of the flow signal being totalized, unless stated as otherwise in
the specifications.
K.Communication Alarms:
1.Provide specific communication status(es) for all Peer-to-Peer data communications.
Upon a Peer-to-Peer communication failure, a communication failure alarm shall be
generated at each PLC for display and alarming at the HMI. This communication failure
alarm shall also be utilized for the associated control strategy.
L.Control Mode Transition:
1.Programming at the PLC shall be such that switching between manual and automatic
control modes results in a smooth transition without upsetting the process or
inadvertently changing equipment states.
2.Equipment running in local manual mode shall be tracked by the PLC code such that
the PLC maintains the running status and speed setpoint when switching the
equipment’s Hand-Off-Auto (or Local-Remote) switch from Hand to Auto (or Local to
Remote). When switching equipment directly into an Automatic PID or sequence type
control function, the PLC shall use the tracking values (running status and speed) as
initial values.
3.If equipment tracking is via peer-to-peer communications (rather than hardwired
interface) and communications link goes down, the PLC shall be programmed to re-
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verify equipment running and speed status before allowing the switch to remote
control mode. This is intended to prevent PLC code from inadvertently shutting down
equipment when communications are restored.
M.PID Tuning Parameters:
1.All tuning parameters for each PLC software PID controller are entered at the HMI.
Tuning trends are provided to tune and monitor each PID operation. Tuning
parameters settings are password protected.
3.03ATTACHMENTS
A.The following Section Attachments are included to provide further details and
requirements for the Applications Development work.
1.40 61 96A PROCESS CONTROL DESCRIPTIONS – ATTACHMENT A - AERATION
BLOWERS AND AERATION BASINS.
2.40 61 96B PROCESS CONTROL DESCRIPTIONS - ATTACHMENT B - RESACA LIFT
STATION
END OF SECTION
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40 61 96A PROCESS CONTROL DESCRIPTIONS – ATTACHMENT A – AERATION BLOWERS
AND AERATION BASINS
1.00GENERAL:
A.There are four existing 250 horsepower, multistage HSI (Atlas Copco) centrifugal blowersat
the Blower Building to furnish air to the four aeration basins. These blowers draw in
atmospheric air and compress it to approximately 10.2 PSI. Each blower is equipped with an
inlet throttling valve to control the air flow. The throttling valve is a motorized butterfly
valve that modulates in accordance with the blower header pressure and the air flow
demand by the aeration basins. Outside air is drawn from outside the building through a
filter system. The four blowers discharge into a common header that is routed to the
aeration basins. Each blower has local safety shutdown switches. These switches shut down
the blower in the event of surge, overload, bearing high vibration, or bearing high
temperature alarm. These switches shall be provided in each of the blower control panel as
described later.
B.One blower is always in service, throttled during normal aeration system operations. The air
flow to each aeration basin is adjusted to maintain the desired dissolved oxygen (DO) levels
in the mixed liquor by the Aeration Basins DO control strategy.
C.Each existing blower is equipped with a Blower Control Panel (BCP) which communicates
with the Master Control Panel (MCP). There is a programmable Logic Controller (PLC) in
each BCP and the MCP. An Operator Interface Terminal (OIT) is located on the door of each
blower panel and the MCP. A Local/Off/Auto switch, Start and Stop pushbuttons, and Alarm
Indicating Light are located on the blower control panel door below the OIT. There is an
Alarm Indicating Light on the master control panel door below the OIT.
D.Each aeration basin has a dissolved oxygen probe at the end of basinin Zone 4. To monitor
and control the DO, one air flowmeter and air flow control valve are provided at each
basin’s inlet air header.
E.Further functionality present in the existing PLC programs not listed below shall be
recreated in the new PLC program. Existing PLC programs shall be made available upon
request.
2.00AERATION BLOWER CONTROL:
A.There will be two modes of Aeration Blower control strategy, Manual and Auto. The
Auto/Manual selection is made from the “Aeration Blowers” screens at the SCADA HMIand
at the OIT.
B.The aeration blower Manual control logic shall be provided in the BCP for each blower. The
Master control logic for all blowers shall be programmed in each MCP.
1.Manual Mode:
a.In Manual mode, the operator starts and stops the blower and adjusts the blower
inlet valve position setpoint between the minimum and maximum position allowed
(initially set at 20% and 80%). The blower shall be started by the control strategy,
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with inlet valve position set at the startup valve position setpoint entered by the
supervisor (initially set at 50%). Once the blower has started and the blower startup
alarm delay timer has expired (explained later), the inlet valve position shall be
ramped open, using the valve rate-of-change value (initially set at 0.5% per second),
until it reaches the operator entered inlet valve position value. The inlet valve
position setpoint shall not exceed its maximum open position allowed. The inlet
valve’s minimum and maximum position value shall be changed by a supervisor
only. An operator shall be allowed to change the inlet valve position setpoint
between the minimum and maximum position values only.
b.In this mode, the operator takes complete control of blowers’ operations. When at
least one aeration basin is in service, one blower must be always in service.
2.Auto Mode:
a.In Auto mode, the 4, MCP automatically designates each blower lead, lag1, lag2, and
lag3 in order of control runtime. Control runtime can be reset from the HMI and is
separate from the maintenance runtime.
b.Blower lead/lag designation shall be continuously assessed, not only when a blower
is off. If, for example, the lead blower with the lowest runtime runs until it is no
longer the blower with the lowest runtime, it will be called to stop according to its
new lag designation, as described in the sections below.
c.The operator also adjusts the blower header pressure setpoint between the
minimum and maximum allowable setpoint value. The minimum and maximum
setpoint limits are adjustable by a supervisor only. All operator and supervisor
inputs shall be entered using the SCADA HMI popup windows. The blower automatic
control strategy shall be programmed in the MCP. All soft commands such as,
start/stop blower, inlet valve position, alarms, setpoints values etc., calculated by
the MCP shall be transferred to individual BCPs as required. Similarly, all soft values
such as blower status, alarms, SCFM calculations, inlet valve positions, etc., that are
needed by the MCP shall be available in each BCP to be read by MCP.
C.The minimum air flow for each blower is 2500SCFM, and the maximum air flow for each
blower is 4500SCFM.
2.01BLOWER DISCHARGE HEADER PRESSURE CONTROL:
A.After the minimum off delay timer (explained later) has expired, the blower must be started
with the inlet valve at a pre-set startup valve position. After the blower is running, and the
blower startup alarms delay timer has expired, the inlet valve shall be gradually opened
(ramped based on the operator entered “Valve Rate of Change” value), until the header
pressure is within the deadband of the operator entered setpoint. To control the header
pressure using the inlet valve position, a closed loop inlet valve control (proportional and
integral, PI) is provided. When the discharge header pressure rises above the operator
entered setpoint (plus deadband), the inlet valve position is adjusted by the PI control until
the pressure is within the deadband. The valve position control is provided with the
minimum and maximum control output values within the PI control. The minimum and
maximum valve position values can be adjusted by a supervisor only. When the discharge
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header pressure drops below the setpoint (minus deadband), the inlet valve position is
adjusted by the PI control until the pressure is within the deadband. When the discharge
header pressure is within the desired setpoint range, the PI control output is unchanged.
B.When the discharge header pressure drops below a pre-set (adjustable) low pressure alarm
setpoint and stays below for a predetermined time and the lead blower’s inlet valve is at
maximum allowable position, the lag1 blower shall be requested to start (with its inlet valve
at a pre-set startup position). Once the lag1 blower is running and the startup alarm delay
timer has expired, its inlet valve shall be ramped slowly to the open position value. Once the
lag1 blower inlet valve has reached an open position which is within the deadband of the
lead blower’s inlet valve position, the lag1 blower’s inlet valve shall be released for PI
control. Note that the lead blower’s inlet valve shall remain under PI control when the lag1
blower is brought online and its inlet valve is ramping to open position.
C.When the lead and lag1 blowers are running and discharge header pressure drops below a
pre-set (adjustable) low pressure alarm setpoint for a predetermined time and the lead and
lag1 blowers’ inlet valves are at maximum allowable position, the lag2 blower shall be
requested to start (with its inlet valve at the pre-set minimum or startup? open position).
Once the lag2 blower is running and the startup alarm delay timer has expired, its inlet valve
shall be ramped slowly to the open position. Once the valve has reached within the
deadband of the lead and lag1 inlet valves’ position, the lag2 blower inlet valve shall be
released for PI control. Note that the lead blower’s inlet valve shall remain under PI control
when the lag1 blower is brought online and its inlet valve is ramping to open position. Note
that the lead and lag1 blowers’ inlet valve shall remain under PI control when the lag2
blower is brought online and its inlet valve is ramping to open position.
D.When the lead, lag1, and lag2 blowers are running and discharge header pressure drops
below a pre-set (adjustable) low pressure alarm setpoint for a predetermined time and the
lead, lag1, and lag2 blowers’ inlet valves are at maximum allowable position, the lag3
blower shall be requested to start (with its inlet valve at minimum or startup position). Once
the lag3 blower is running and the startup alarm delay timer has expired, its inlet valve shall
be ramped slowly to the open position. Once the valve has reached within the deadband of
the lead, lag1, and lag2 inlet valves’ position, the lag3 blower inlet valve shall be released for
PI control. Note that the lead, lag1, and lag2 blowers’ inlet valves shall remain under PI
control when the lag3 blower is brought on line and its inlet valve is ramping to open
position.
E.NOTE – When trying to control the header pressure, the inlet valve position must always be
ramped open and ramped close in Manual and Auto modes (by the control strategy). This
will help in avoiding the surge or overload conditions by opening or closing the valve quickly.
F.When all blowers are running, and if the discharge header pressure rises above a pre-set
(adjustable) high pressure alarm setpoint and stays above for a predetermined time, the
lag3 blower shall be requested to stop. When the lag3 blower has stopped, its inlet valve
shall be removed from PI control and the valve shall be requested to close at the minimum
allowable position.
G.When the lead, lag1, and lag2 blowers are running and the discharge header pressure rises
above a pre-set (adjustable) high pressure alarm setpoint and stays above for a
predetermined time, the lag2 blower shall be requested to stop. When the lag2 blower has
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stopped, its inlet valve shall be removed from PI control and the valve shall be requested to
close at the minimum allowable position.
H.When the lead and the lag1 blowers are running, and the discharge header pressure rises
above a pre-set (adjustable) high pressure alarm setpoint and stays above for a
predetermined time, the lag1 blower shall be requested to stop. When the lag1 blower has
stopped, its inlet valve shall be removed from PI control and the valve shall be requested to
close at the minimum allowable position.
I.When a blower has run continuously for seven days or more, the next blower in priority
shall be started and the continuously running blower shall be requested to stop.
J.When a blower is requested to start and fails to start, the next blower in priority shall be
started and the operator is notified by an alarm message (discrepancy alarm). Similarly, if a
blower is stopped without a command from the control strategy, while running, the next
blower in priority shall be started, if required, and the operator is notified by an alarm
message (deviation alarm).
2.02BLOWER STARTUP ALARM DELAY TIMER:
A.During the blower startup, a startup alarm delay timer for each blower shall be provided
which shall deactivate all alarms associated with the blower accept the temperature. Once
the blower has reached its normal operating state and the timer has expired, allow all
alarms to be activated
2.03 AERATION BASIN IN-SERVICE:
A.Blower(s) shall be locked out from starting if none of the Aeration Basins are in-service.
Operator shall be allowed to put an aeration basin in or out of service from the SCADA HMI
Aeration Basins screens.
2.04 BLOWER AUTOMATIC RESTART:
A.To re-start a blower, upon a power failure, an automatic restart switch shall be provided on
the SCADA HMI Aeration Blowers screens. When the switch is in “ON” position, the blower
shall automatically restart, if previously on regardless of control modes (Auto or Manual).
B.The Minimum Time Off timer shall be in effect in both Auto and Manual modes and will start
counting down from the time power is restored.
C.If the switch is in “OFF” position, the blower shall not be restarted automatically when the
power is restored regardless of control modes (Auto or Manual).
D.The operator must first put the control strategy in Manual (if not already in Manual) to
restart a blower after a power failure.
E.The strategy can now be put in Auto mode for header pressure control.
F.Blower Alarms and Shutdown:
1.Blower Surge Alarm – When the blower amps drop below the supervisor entered
setpoint a surge alarm timer shall be started. If the blower amps remain below this
setpoint and the surge timer expires, an alarm shall be activated, and operator notified.
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2.Blower Surge Shutdown Alarm – When blower amps drop below the supervisor entered
setpoint a surge shutdown timer shall be started. If the blower amps remain below this
setpoint and the surge shutdown timer expires, an alarm shall be activated, and the
blower shall shut down.
3.Blower Overload Alarm - When the blower amps rise above the supervisor entered
setpoint an overload alarm timer shall be started. If the blower amps remain above this
setpoint and the overload timer expires, an alarm shall be activated, and operator
notified.
4.Blower Overload Shutdown Alarm – When the blower amps rise above the supervisor
entered setpoint an overload shutdown alarm timer shall be started. If the blower amps
remain above this setpoint and the overload shutdown timer expires, an alarm shall be
activated, and the blower shall shutdown.
5.Blower InBoard Vibration Alarm – If the blower inboard vibration exceeds the supervisor
entered setpoint, an inboard vibration alarm timer shall begin. If the blower inboard
vibration remains above this setpoint and the inboard vibration alarm timer is expired,
an alarm shall be activated, and operator notified.
6.Blower InBoard Vibration Shutdown – If the blower inboard vibration exceeds the
supervisor entered setpoint, an inboard vibration shutdown timer shall be started. If the
blower inboard vibration remains above this setpoint and the inboard vibration
shutdown timer is expired, the blower shall shutdown, an alarm is generated, and
operator notified.
7.Blower OutBoard Vibration Alarm – If the blower outboard vibration exceeds the
supervisor entered setpoint, an outboard vibration alarm timer shall begin. If the blower
outboard vibration remains above this setpoint and the outboard vibration alarm timer
is expired, an alarm shall be activated, and operator notified.
8.Blower OutBoard Vibration Shutdown – If the blower outboard vibration exceeds the
supervisor entered setpoint, an outboard vibration shutdown timer shall be started. If
the blower outboard vibration remains above this setpoint and the outboard vibration
shutdown timer is expired, the blower shall shutdown, an alarm is generated, and
operator notified.
9.Blower InBoard Temperature Alarm – If the blower Inboard temperature exceeds the
supervisor entered setpoint, an inboard temperature alarm timer shall begin. If the
blower inboard temperature remains above this setpoint and the inboard temperature
alarm timer is expired, an alarm shall be activated, and operator notified.
10.Blower InBoard Temperature Shutdown – If the blower Inboard temperature exceeds
supervisor entered setpoint, an inboard temperature shutdown timer shall begin. If the
blower inboard temperature remains above this setpoint and the inboard temperature
shutdown timer is expired, the blower shall shutdown, an alarm shall be activated, and
operator notified.
11.Blower OutBoard Temperature Alarm – If the blower outboard temperature exceeds
supervisor entered setpoint, an outboard temperature alarm timer shall begin. If the
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blower outboard temperature remains above this setpoint and the outboard
temperature alarm timer is expired, an alarm shall be activated, and operator notified.
12.Blower OutBoard Temperature Shutdown – If the blower outboard temperature
exceeds supervisor entered setpoint, an outboard temperature shutdown timer shall
begin. If the blower outboard temperature remains above this setpoint and the
outboard temperature shutdown timer is expired, the blower shall shutdown, an alarm
shall be activated, and operator notified.
2.05 BLOWER MINIMUM OFF TIME:
A.The blower must remain off after it has been shutdown for any reason. This allows time for
the motor to stop spinning, prevents rapid cycling, reduces excessive heating from quick
starts, etc. This timer value shall be changeable by a supervisor only.
2.06 INLET VALVE CONTROL:
A.Each blower’s inlet valve is controlled under the blower control strategy. When the strategy
is in Manual mode, the operator is allowed to start/stop blower and change its inlet valve
position. In Auto mode the blower is started/stopped automatically, and its inlet valve
position is changed using a closed loop PI controller. The closed loop PI controller controls
all inlet valves’ position of the running blowers using the header pressure as the process
variable. To avoid surge and overload conditions, in both modes (Auto and Manual) the
valve must be ramped open and ramped close using the ”rate-of change” operator setpoint.
In Manual mode the PI control is suspended, and for a bumpless transfer, the PI control
tracks the valve position. In Auto mode the PI controller output is corrected during the
surge, overload and minimum valve position allowed as described below.
1.Minimum Valve Position Setpoint:
a.During the inlet valve control, to avoid surge conditions, the minimum valve position
setpoint shall limit how far the valve is allowed to close. This limit shall take
precedence in both the Manual and Auto modes.
2.Maximum Valve Position Setpoint:
a.During the inlet valve control, to avoid overload conditions, the maximum valve
position setpoint shall limit how far the is allowed to open. This limit shall take
precedence in both Manual and Auto modes.
3.Blower Startup Valve Position Setpoint:
a.During the blower startup the blower inlet valve must be opened to this operator
entered setpoint.
4.Valve Rate of Change Setpoint:
a.During the inlet valve control, to avoid surge and overload, the valve shall be
ramped open and closed using this setpoint. This rate of change takes precedence in
both Manual and Auto modes.
5.Overload/Surge Prevention:
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a.When the blower’s amps exceed the overload alarm values then the inlet valve shall
start to close 1% every second, and valve overload clamping timer shall begin, until
the amps value reaches below the alarm value. This establishes a High Amp
Clamping Value. The clamp setting shall be released after the valve overload
clamping timer has expired. This will allow the valve to open more, if necessary,
based on the PI control output. A new clamp setting shall be re-established at the
next alarm condition.
b.This High Amp Clamp value limits how far the valve will be allowed to open while
the High Amp Clamp value is in effect.
c.After a clamp setting has been established and if the amps again exceed the alarm
value, and even though the valve overload clamping timer has not expired, a new
clamping value shall be re-established by closing the valve at 1% intervals as
described earlier.
a)Similar logic as described above shall be provided for Surge Conditions to
establish a Low Amp Clamping Value upon low amp condition.
d.Note that the Overload/Surge Prevention shall not override the output signal when
in the Manual control mode.
e.Entering a value of zero (0) for the above timers shall disable the Surge/Overload
Prevention logic and the High/Low Amp Clamp values.
2.07 CALCULATIONS:
A.Blower Discharge Total Air Flow:
1.The discharge flow to each running blower shall be calculated. The SCFM is calculated
th
based on actual blower Amps reading and a 4 degree polynomial. All running blowers
calculated discharge flows shall be added (summed) and displayed at the HMI.
2.The following equation shall be used to calculate each blower’s SCFM output:
432
SCFM = A * Amps + B * Amps + C * Amps + D * Amps + E
3.The values for A, B, C, D, and E will be provided during submittal process.
B.Aeration Basin Inlet Air Flows:
1.All on-line aeration basins’ metered air flows shall be added (summed) and displayed on
the screen(s). The blowers’ total air flows shall be compared with the aeration basins’
total air flows. If the difference between the two values exceeds an operator entered
setpoint, an alarm shall be generated, and operator notified.
2.08 FAILURE CONTINGENCIES:
A.Blower Fail
1.During the blower startup or steady state a blower failure shall cause the next blower in
the sequence to start. A blower shall become not controllable due to blower fail alarms.
B.Blower Permissive:
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1.The following permissive signals must be satisfied before a blower can start:
a.Blower in remote (auto) position
b.Blower Minimum Off Delay Timer has expired
c.Blower inlet or out Temperature is not in high condition
d.Blower inlet valve is at the minimum allowed position
2.Blower Inlet Valve Fails:
a.During the blower startup or steady state if the blower inlet valve fails to respond,
the blower shall be stopped, and an alarm shall be generated to inform the
operator. The blower next in sequence shall be started.
a)Blower Current Transmitter Fail
b)When a blower’s current (amp) transmitter fails, an alarm shall be
generated and all calculations using the current value shall freeze at the last
good value.
2)Blower InBoard Temperature Transmitter Fail
a)When a blower’s inboard temperature transmitter fails, an alarm shall be
generated and all calculations using this value shall freeze at the last good
value.
3)Blower OutBoard Temperature Transmitter Fail
a)When a blower’s outboard temperature transmitter fails, an alarm shall be
generated and all calculations using this value shall freeze at the last good
value.
4)Blower InBoard Vibration Transmitter Fail
a)When a blower’s inboard vibration transmitter fails, an alarm shall be
generated and all calculations using this value shall freeze at the last good
value.
5)Blower OutBoard Vibration Transmitter Fail
a)When a blower’s outboard vibration transmitter fails, an alarm shall be
generated and all calculations using this value shall freeze at the last good
value
6)Blower Discharge Header Pressure Transmitter Fail:
a)When the discharge header pressure transmitter fails, the blower PI control
shall freeze at its last good value. An alarm shall be generated notifying the
operator that blower control strategy has been suspended due to the
header pressure transmitter failure.
2.09 COMMUNICATION ALARMS:
A.SCADA to PLC Communication Fail Alarm:
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1.Any time the SCADA and any PLC can’t communicate, an alarm shall be generated
notifying the operator that PLCX is not communicating with SCADA.
B.PLC to PLC Communication Fail Alarm:
1.There are instances where a PLC is reading values from another PLC for monitoring and
control, called peer-to-peer communication. For example, Master Control Panel is
communicating with the Blower Control Panels continuously for calculations and
control.
2.Any time a PLC is not communicating with another PLC, an alarm shall be generated
notifying the operator. The operator shall take the appropriate actions until the issue
has been resolved.
3.Any time a BCP PLC is not communicating with the MCP PLC for an adjustable length of
time, the BCP shall automatically place the blower in manual control mode.
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3.00AERATION BASINS DO/AIR FLOW CONTROL:
A.There are two modes of Dissolved Oxygen control strategy, Manual and Auto. The
Auto/Manual Mode selection is made from the “Aeration Basins” screens. Each aeration
basin’s DO/Air is controlled by the strategy dedicated to each basin. Therefore, there shall
be four individual control strategies, one for each basin.
B.These control strategies shall be programmed in Master Control Panel PLC.
3.01 MANUAL MODE:
A.In Manual mode, the operator adjusts the position of each basin’s air flow control valve for
desired air flow and hence the DO. The air flow valve’s minimum and maximum position
setpoint shall be provided changeable by a supervisor only. To protect the diffusers in each
basin, a maximum air flow limit to each basin shall be set. The maximum will be determined
during construction in coordination with the diffuser manufacturer.
3.02 AUTO MODE:
A.In Auto mode, the operator selects the DO or Air Flow control for each of the basins. In Auto
mode, the control strategy positions the aeration basins’ air inlet valves as required
maintaining DO or air flow automatically. The operator shall be allowed to enter the DO and
Air Flow setpoints, for each aeration basin from the aeration basins’ displays at the SCADA
HMI screens.
3.03 DO/AIR FLOW CONTROL MODE SELECTION (FOR EACH AERATION BASIN):
A.The operator shall be allowed to select between DO control or Air Flow control for each
basin separately. When the operator selects the DO Control Mode for Aeration Basins, the
air flow is controlled automatically to maintain the desired DO setpoint. DO and Air Flow
Control shall be programmed in a cascaded loop, where DO loop is the “outer loop”, and the
air flow is the “inner loop”. When the operator selects the Air Flow control, the DO control
shall be suspended and shall execute in “tracking mode” for a bumpless transfer.
B.DO Control Mode:
1.Closed loop DO control (proportional & integral, PI) cascaded with the closed loop air
flow control (proportional & integral, PI) shall be provided when DO control is selected.
The aeration basin DO transmitter value shall be used as the process variable, to
maintain the DO setpoint. The DO setpoint shall be provided with upper and lower limits
that can be changed by a supervisor only.
2.In this mode, if the DO transmitter fails, the strategy shall switch to Air Flow control
automatically using the last good value from the DO controller. An alarm shall be
generated, and operator notified. During the DO transmitter failure, the operator shall
be allowed to change the air flow setpoint when needed. The operator must put the
strategy back in Auto when the DO transmitter is working properly.
C.Air Flow Control Mode:
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1.When the operator selects the Air Flow control mode, the DO control shall be
suspended, and the DO control loop shall execute in tacking mode for a bumpless
transfer. The aeration basin influent air flow shall be used as the process variable to be
maintained. The air flow setpoint shall be provided with upper and lower limits that can
be changed by a supervisor only. The strategy shall maintain the aeration basin’s airflow
by varying position of aeration basin’s inlet air flow valve.
2.Regardless of control selected by the operator (DO or Air Flow), the air flow control
output from the DO control loop (DO PI) shall be provided with upper and lower limits
that can be changed by a supervisor only. Similarly, the air flow control loop (Air Flow PI)
output to the valve shall be provided with upper and lower limits that can be changed
by a supervisor only.
3.Aeration basins’ inlet air flow control valve position control shall be provided with upper
and lower limits that can be changed by a supervisor only.
D.Total Air Flow to Aeration Basins:
1.Inlet air flows to all in service aeration basins shall be combined and displayed at the
HMI.
E.Aeration Basin in Service:
1.DO/Air Flow control shall be suspended for an aeration basin that is out of service. The
closed control loops for DO and air flow shall execute in tracking mode for a bumpless
transfer. The operator shall be allowed to put an aeration basin in or out of service from
each aeration basin’s SCADA HMI screen.
3.04 FAILURE CONTINGENCIES:
A.DO Transmitter Fail:
1.If the DO transmitter fails, the strategy shall generate an alarm to notify operator. The
strategy shall switch to air flow control mode automatically and suspend DO control
mode.
B.Air Flow Transmitter Fail:
1.During DO or air flow control mode if the air flow transmitter fails, the strategy shall
alarm and notify the operator. All outputs from DO and air flow control loops shall
freeze and continue to maintain the last output. The operator shall switch the strategy
to Manual mode for operation until the problem is corrected.
C.Air Flow Alarm:
1.Add all running blowers’ calculated discharge air flows and add all in service aeration
basins’ inlet air flows and compare the two values. If the two values are differed by
more than the operator entered setpoint, an alarm shall be generated.
D.Basin Air Flow Control Valve Fail:
1.During the DO or air flow control if the basin air flow valve fails, the strategy shall freeze
the last output to the valve. An alarm shall be generated to inform the operator. The
operator may need to take the basin out of service until the valve is back in service.
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3.05 SCADA INPUTS AND OUTPUTS
A.Refer to the P&ID Drawings and Division 40 Input/Output List for field and digital
input/output points associated with these strategies.
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40 61 96B PROCESS CONTROL DESCRIPTIONS – ATTACHMENT B – RESACA LIFT STATION
1.00GENERAL:
A.The existing Resaca pump station receives raw wastewater (RWW) from multiple sewage lift
stations located throughout the city. Two 48-inch inlet pipes carry the RWW into two wet
wells from the remote lift stations. The two wet wells are called East wet well and West wet
well. These wet wells are connected by a 36-inch isolation sluice gate which is normally
open keeping the RWW level equal (hydraulically). Each existing wet well has three 215HP
variable speed pumps. The East side wet well has pumps 1, 2, and 3. The West side wet well
has pumps 4, 5, and 6. Each set of the three pumps discharge into a common header. The
two discharge headers are connected by a normally open isolation valve. These pumps
discharge into the headworks via two 24-inch lines.
2.00RAW WASTEWATER PUMPS CONTROL:
A.There are two modes of Raw Wastewater Pumps at Resaca Lift Station control strategy,
Manual and Auto. The Auto/Manual mode selection shall be made from the Resaca List
Station Pump Control Cabinet Operator Interface Terminal (OIT) or the SCADA HMI screens.
B.For wet wells level control, two level indicating transmitters, one for each well, are provide
at the wet wells, East and West. For plant influent flow control, two flow meters, one on
each 24-inch pipe, entering the headworks are provided. Each flow and the combined flow
shall be displayed at the OIT and SCADA HMI screens.
2.01MANUAL MODE:
A.In Manual mode, the operator shall start and stop the pumps based upon the wet well level.
In Manual mode, the operator shall adjust the speed of pumps to maintain the wet wells
level or for the required influent flow to the plant.
2.02AUTO MODE:
A.In Auto mode, the PLC automatically designates each pump lead, lag1, lag2, lag3, lag4, and
lag5 in order of control runtime. Control runtime can be reset from the HMI and is separate
from the maintenance runtime. Pump lead/lag designation shall be reassessed for a given
pump only when it is off.
B.In Auto mode, the operator selects the Level or Flow control. The control strategy shall start,
stop, and adjust the speed of pumps automatically as required by the process.
3.00LEVEL CONTROLMODE:
A.In the Level Control Mode, the operator shall be able to select one of the two level
transmitters provided in East and West wet wells for control.
1.The operator shall be able to enter start and stop level setpoints for each lead/lag
setpoints for each pump designation (lead, lag1, lag2, lag3) from the SCADA HMI
screen’s popup windows.
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B.Closed loop level control (proportional & Integral, PI) shall be provided. The level signal, as
selected by the operator shall be used for control. The level setpoint shall be provided with
upper and lower limits that can be changed by a supervisor only. The output of this PI
control shall be used by all running pumps simultaneously. The speed output of this PI
control shall be used by all running pumps simultaneously.
1.The maximum speed that a pump will automatically be called to run at is 95%. The
minimum speed that a pump will automatically be called to run at is 35%. When the
currently running pumps cannot reach the flow setpoint entered by the operator, a
pump will be called to start or stop as described in Section 4.00, D below.
C.Maximum of three pumps shall be allowed to operate at the lift station due to the maximum
flow capacity of the plant. The other two pumps shall be used in case of selected pumps fail
to operate.
D.The lead pump must always be running. If the lead pump fails, the lag1 pump shall start. If
the wet well level starts to rise and reaches an operator entered high alarm setpoint an
adjustable predetermined timer (initial time setpoint to be determined during construction)
is started, and the operator is notified. The operator has two choices – ignore the timer and
start the next pump in sequence manually or let the timer expire. The pump shall start
automatically after the timer is expired. During the timer countdown, if the condition that
required another pump to start is no longer present, the timer is reset, and the start
command is not sent. If the wet well level started to drop and reaches an operator entered
low alarm setpoint an adjustable predetermined timer (initial time setpoint to be
determined during construction ) is started, and the operator is notified. The operator has
two choices – ignore the timer and stop the pump with lowest priority manually or let the
timer expire. The pump shall stop automatically after the timer is expired. During the timer
countdown, if the condition that required a pump to stop is no longer present, the timer is
reset, and the stop command is not sent.
E.During level control, if the selected level transmitter fails, the strategy shall automatically
switch to the other level transmitter and an alarm shall be generated at the OIT and SCADA
HMI to inform the operator. If both level transmitters are failed, then the strategy shall use
the last good value of level and freeze all outputs. An alarm shall be generated to inform the
operator. When one or both level transmitters are back in operation, the strategy shall
begin controlling the pump control based on the selected level transmitter.
F.At 5 feet wet well level, all pumps shall be stopped and locked out from starting. A low-level
alarm, hardwired to the PLC, is provided as a back up to level transmitters. At low-level
alarm all RWW pumps shall be stopped and locked out until the level rises for the lead pump
to start.
4.00PLANT INFLUENT FLOW CONTROL:
A.In Flow Control Mode, the operator shall be able to enter a Plant Influent Flow Setpoint. The
flow control setpoint shall be provided with upper and lower limits that can be changed by a
supervisor only. The strategy shall maintain the flow by starting/stopping and varying the
speed of pumps.
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B.To control the plant influent flow a closed loop (Proportional & Integral, PI) control, shall be
provided. The lift station discharge flowmeters‘ values shall be combined and used as a
process variable to maintain the plant influent flow. The speed output of this PI control shall
be used by all running pumps simultaneously.
1.The maximum speed that a pump will automatically be called to run at is 95%. The
minimum speed that a pump will automatically be called to run at is 35%. When the
currently running pumps cannot reach the flow setpoint entered by the operator, a
pump will be called to start or stop as described in Section 4.00, D below.
C.Maximum of three pumps shall be allowed to operate at the lift station due to the maximum
flow capacity of the plant. The other two pumps shall be used in case of selected pumps fail
to operate.
D.The lead pump must always be running. If the lead pump fails, the lag1 pump shall start. If
the flow falls below the operator entered flow setpoint by an adjustable limit, an adjustable
predetermined timer (initial time setpoint to be determined during construction) is started,
and the operator is notified. The operator has two choices – ignore the timer and start the
next pump in sequence manually or let the timer expire. The next pump in the lead/lag
sequence shall start automatically after the timer is expired. During the timer countdown, if
the condition that required another pump to start is no longer present, the timer is reset,
and the start command is not sent. If the flow exceeds the operator entered flow setpoint
by an adjustable limit, an adjustable predetermined timer (initial time setpoint to be
determined during construction) is started, and the operator is notified. The operator has
two choices – ignore the timer and stop the pump with lowest priority manually or let the
timer expire. The pump shall stop automatically after the timer is expired. During the timer
countdown, if the condition that required a pump to stop is no longer present, the timer is
reset, and the stop command is not sent.
E.At 5 feet wet well level, all pumps shall be stopped and locked out from starting. A low-level
alarm is provided as a back up to level transmitters. At low-level alarm all RWW pumps shall
be stopped and locked out. Once the level rises above 7 feet, the operator must reset the
lock out alarm for the lead pump to start.
5.00CALCULATIONS:
A.Plant Influent Flow (summed): Both flow transmitters shall be added and displayed on the
OIT and SCADA HMI screens. “Total Influent Flow” shall be calculated by summing the two
plant influent flow meter values.
B.Total Plant Influent Flow: The summed flow shall be totalized for the following periods:
1.Since midnight
2.Yesterday’s total and
3.Total without Reset
C.See “General Narrative” section for all calculations and alarms.
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6.00FAILURE CONTINGENCIES:
6.01PUMP FAIL:
A.During the pump startup or steady state, a pump failure shall cause the next pump to start
in the sequence. A pump shall become not controllable due the pump or VFD failure alarms.
6.02PUMP PERMISSIVE:
A.The following permissive signals must be satisfied before a pump can start:
1.Wet well is not at low level
2.Pump in remote (auto) position
3.Pump is not in overload condition
4.VFD is not failed
6.03LEVEL TRANSMITTER FAIL:
A.There are two wet wells at the Lift Station. Each wet well is provided with a level transmitter
(0-30 FT). Wet well levels are relatively equal because both wet wells are connected via a
sluice gate which is normally open. The operator shall be allowed to select one of the two
level transmitters for control. If the selected level transmitter fails, the strategy shall switch
to the other level transmitter automatically and alarm shall be generated to notify the
operator. If both level transmitters at the List Station wet wells fail, the strategy shall freeze
the last good level value. Alarms shall be generated to notify the operator.
B.A low-level alarm (below 5 feet) is provided to stop all pumps. All pumps shall be locked out
from starting when this condition occurs. The low-level alarms must be reset for the lead
pump to start.
6.04FLOW TRANSMITTER FAIL:
A.The raw wastewater is discharged into two headers, East and West from each wet well.
There are two flow transmitters, one on each header pipe. Both flow transmitters are
combined for flow control using variable pumps’ speed. If any of the flow transmitters fail,
the strategy shall alarm the operator and maintain the last good output value. The operator
shall switch the control to Manual mode until the flow transmitter(s) are back online.
7.00COMMUNICATION ALARMS:
A.SCADA to PLC Communication Fail Alarm:
a.Any time the SCADA and any PLC can’t communicate, an alarm shall be generated
notifying the operator that PLCX is not communicating with SCADA.
B.PLC to PLC Communication Fail Alarm:
a.There are instances where a PLC is reading values from another PLC for monitoring
and control, called peer-to-peer communication. For example, Resaca Lift Station
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PLC is communicating with the PLC3 to receive Plant Influent Flows, continuously for
calculations and control.
b.Any time a PLC is not communicating with another PLC, an alarm shall be generated
notifying the operator. The operator shall take the appropriate actions until the
issue has been resolved.
8.00SCADA INPUTS AND OUTPUTS:
A.Refer to the P&ID Drawings and Division 40 Input/Output List for field and digital
input/output points associated with these strategies.
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40 63 00 PLC HARDWARE AND SOFTWARE
1.00GENERAL
1.01SCOPE OF WORK
A.This Section includes programmable logic controllers (PLCs), Operator Interface Terminals
(OITs), and Gateway Units (Modbus/RS232/RS485 to Ethernet IP converters) for control of
process equipment, process oriented machinery, and process systems.
B.The attached schedule provides details for the replacement PLC systems at each project
site. The quantities shown are to be provided at a minimum, but understanding that
additional hardware may be required and deviations from the hardware quantities listed
may be required because of space restrictions or other unforeseen installation constraints.
1.02RELATED WORK
A.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
B.Refer to Section 40 67 00, Control Panels and Components.
1.03SUBMITTALS
A.Refer to Division 01 for general submittal requirements.
B.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions.
C.Product Data. For each type of PLC, include dimensions, mounting arrangements, and
weights. Also, include manufacturer's technical data on features, performance, electrical
ratings, characteristics, and terminal connections.
D.Operation and Maintenance Data. Provide literature detailing routine maintenance
requirements (if any) for each PLC component including the following.
1.System specifications.
2.Electrical power requirements.
3.Application considerations.
4.Assembly and installation procedures.
5.Power-up procedures.
6.Programming procedures.
7.Explanation of internal fault diagnostics.
8.Troubleshooting procedures.
9.Shutdown procedures.
10.Recommended spare parts list.
1.04REFERENCE STANDARDS
A.National Electrical Safety Code (NESC).
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B.Occupational Safety and Health Administration (OSHA).
C.ANSI/ISA-5.06.01 Functional Requirements Documentation for Control Software
Applications.
D.Isa 5.4 Instrument Loop Diagrams.
E.ASTM D999-91: Vibration.
F.Code of Federal Regulations (CFR) Title 47: Telecommunication, Part 18: Industrial,
Scientific and Medical Equipment – RF Disturbance (European EN 55011 (formerly CISPR
11)).
G.CSA Certification Class I, Division 2, Group A, B, C, D Hazardous or non-hazardous locations.
H.IEC 60068-2.1: Environmental Testing – Part 2-1: Tests - Test A: Cold, 2.2 Environmental
testing - Part 2: Tests. Tests B: Dry heat, 2.3, 2.6 Environmental Testing - Part 2: Tests - Test
Fc: Vibration (sinusoidal) and 2.27 Environmental Testing. Part 2: Tests. Test Ea and
guidance: Shock.
I.IEC 61000 Electromagnetic Compatibility (EMC) - Testing and Measurement Techniques.
J.Part 4-2: Electrostatic discharge immunity test.
K.Part 4-3: Radiated, radio-frequency, electromagnetic field immunity test.
L.Part 4-4: Electrical fast transient/burst immunity test.
M.Part 4-5: Surge immunity test.
N.Part 4-6: Immunity to conducted disturbances, induced by radio-frequency fields.
O.IEC 801-3: RFI Immunity.
P.IEC 801-5: Ground Continuity.
Q.IEC 801-2: Electrostatic Discharge.
R.IEC 61131-3: Programmable Controllers - Part 3: Programming Languages.
S.IEEE 472-1974/ANSI C37.90/90A-1974 (Surge Withstand) IEEE Standard for Relays and
Relay Systems Associated with Electric Power Apparatus.
T.MIL STD 461B CS02: RFI/EMI Susceptibility.
U.National Fire Protection Association (NFPA).
V.NFPA 79 Electrical Standard for Industrial Machinery.
W.NFPA 70 National Electrical Code (NEC).
X.NFPA 70E Standard for Electrical Safety in the Workplace.
Y.National Electrical Manufacturers Association (NEMA).
Z.NEMA Pub. No. ICS2-230.42: Showering Arc Test.
AA.AA. NSTA Project 1A.
BB.BB. UL 508 and CSA Standard C22.2 No. 142 (Isolation Voltages).
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1.05QUALITY ASSURANCE
A.Manufacturer Qualifications. A qualified manufacturer shall be capable of providing
training, parts, and coordination of emergency maintenance and repairs.
B.The manufacturer of this equipment shall have produced similar equipment for a minim
period of five years. When requested by the OWNER/ENGINEER, an acceptable list of
installations with similar equipment shall be provided demonstrating compliance with this
requirement.
C.Have a local office within one hundred (100) miles of the City of San Antonio or have
technicians available on-site within four hours of emergency notification.
D.Have a local full-time staff of employees that have developed and commissioned a
minimum of three new Allen Bradley based systems within the past 12 months. Must have
a minimum five years’ experience designing, installing, and commissioning SCADA systems.
E.Have a minimum of three full-time employees qualified to perform the SCADA system
configuration work.
F.The programmable controller and all of the corresponding components within the family of
controller products shall be manufactured by a company who regularly manufactures and
services this type of equipment.
G.The manufacturer shall comply with ISO 9001 standards for "Quality Systems- Model for
Quality Assurance in Design/Development, Production, Installation, and Servicing".
H.The manufacturer shall provide complete technical support for all of the products. This
shall include factory or on-site training, regional application centers, local or factory
technical assistance, and a 24/7/365 technical support phone service.
1.06DELIVERY, STORAGE, AND HANDLING
A.Deliver PLC components in packaging designed to prevent damage from static electricity
and physical damage.
B.Store PLC equipment according to manufacturer requirements. At a minimum, store
indoors in clean, dry space with uniform temperature to prevent condensation. Protect
PLCs from exposure to dirt, fumes, water, corrosive substances, and physical damage. Also,
protect the PLC from all forms of electrical and magnetic energy that could reasonably
cause damage.
1.07NOMENCLATURE AND IDENTIFICATION DEFINITIONS
A.AI: Analog Input.
B.AO: Analog Output.
C.Fixed I/O: A PLC style consisting of a fixed number of I/O, a processor, and a power supply
all in one enclosure. Some fixed PLCs have limited expansion ability.
D.CPU: Central Processing Unit.
E.DI: Discrete Input.
F.Distributed I/O: Hardware specially designed to function as Remote I/O.
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G.DO: Discrete Output.
H.HMI: Human-Machine Interface.
I.I/O: Input and/or Output.
J.Modular I/O: A PLC style consisting of cards that are assembled to comprise a complete
unit. All I/O, CPU, and Power Supply are dedicated cards. Typically, these cards are inserted
into a chassis.
K.Master/Slave: Communication between devices in which one device, the master, controls
all communications. The other devices, the slaves, respond only when queried by the
master. Typically used in a Remote I/O application.
L.Peer-to-Peer: Communication between two or more devices, typically PLCs, in which each
device can control the communication exchange.
M.PID: Control action, proportional plus integral plus derivative.
N.PLC: Programmable Logic Controller.
O.Remote I/O: I/O that is located remotely from the processor. Remote I/O can communicate
over a variety of communication protocols and can use standard rack based I/O, or special
Remote I/O hardware referred to as Distributed I/O.
P.SCADA: Supervisory Control and Data Acquisition.
1.08WARRANTY
A.Provide warranty per Division 01, Warranties and Bonds, and as specified herein.
B.The Manufacturer shall warrant the equipment to be free from defects in material and
workmanship for two years from date of acceptance of the equipment containing the items
specified in this Section. Within such period of warranty the Manufacturer shall promptly
furnish all material and labor necessary to return the equipment to new operating
condition. Any warranty work requiring shipping or transporting of the equipment shall be
performed by the CONTRACTOR at no expense to the OWNER.
1.09SPARE PARTS
A.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions, SPARE PARTS.
B.All spare parts shall be packaged to prevent damage during long-term storage. Identify all
packages with indelible markings on the exterior describing contents.
C.Provide complete ordering information including manufacturer, part number, part name,
hardware and software revision levels, and equipment for which the part is to be used.
1.10SPARE I/O
A.Refer to Section 40 61 93, Process Control System – Input/Output List for summaries of I/O
type quantities for each PLC.
B.Spare output points that require the use of an external relay shall include provision of that
external relay.
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C.All installed unused points on all I/O modules shall be wired to terminal blocks in the order
that they occur on the I/O modules. Unwired spares shall not be acceptable.
2.00PRODUCTS
2.01GENERAL
A.Provide PLC equipment with the maximum memory available from the manufacturer for
functional capacity (logic programming) to perform the specified sequence of operation
with the scheduled input and output points.
B.PLC systems shall include processor, memory cards, power supplies, input/output modules,
communication modules, redundancy modules, and remote interface modules as required
to satisfy project requirements.
1.Provide memory cards for all PLC CPUs provided on this project.
C.Furnish products listed and classified by Underwriters Laboratories (UL), CSA, or FM
approval as suitable for purpose specified and indicated.
D.All equipment and devices, furnished hereunder, shall be designed for continuous industrial
service. The system shall contain products of a single manufacturer, insofar as possible, and
shall consist of equipment models that are currently in production.
E.The PLCs shall communicate between the HMI Server and field-mounted transducers,
switches, controllers, and process actuators. Communications protocol shall be completely
transparent to process operators at the HMI.
F.All equipment furnished shall be designed and constructed so that in the event of power
interruption the systems shall go through an orderly shutdown with no loss of memory, and
resume normal operation without manually resetting when power is restored. The PLC shall
be capable of stand-alone operation in the event of failure of the communication link to the
HMI subsystem.
G.Remote Input/Output Units shall include input/output modules, interface modules,
communication modules, and power supply to meet system input and output
requirements.
H.Agency and Environmental Specifications
1.Electrical supply voltage to the PLC shall be 120 VAC plus or minus 15 percent, 48-
63Hz. PLC system power supplies shall be fused for overload protection.
2.Vibration: 3.5 mm Peak-to-Peak, 5-9 Hz: 1.0G, 9-150\\Hz. The method of testing is to be
based upon IEC 68-2-6 and JIS C 0911 standards for vibration. The system is to be
operational during and after testing. Vibration Rating of 2.0G maximum peak
acceleration for 10 to 500Hz, in accordance with at least one of the following:
a.Installed rating: DIN rail mounted PLC: 10-57 Hz, amplitude 0.075 mm,
acceleration 25-100 Hz.
b.Panel- or plate-mounted PLC: 2-25 Hz, amplitude 1.6 mm, acceleration 25-200 Hz.
c.In compliance with IEC 60068 and IEC 61131.
3.Shock: 15G, 11 msec. The method of testing is to be based upon IEC 68-2-27 and JIS C
0912 standards for shock. The system is to be operational during and after testing.
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4.Temperature: All PLC hardware shall operate at an ambient temperature of 0 to +55
degrees C (+32 to +140 degrees F), with a storage ambient temperature rating of -25
to +70 degrees C (-40 to +185 degrees F).
5.Relative Humidity: The Programmable Controller hardware shall function continuously
in the relative humidity range of 30 percent to 95 percent non-condensing.
6.Noise Immunity: The Programmable Controller system shall be designed and tested to
operate in the high electrical noise environment of an industrial plant as governed by
the following regulations: IEEE 472, IEC 801, MILSTD 461B, IEC 255-4, NEMA ICS 2-
230.40, and ANSI/IEEE C-37.90A-1978.
7.Altitude
a.Operation: 0-6,500 feet.
b.Storage: 0-9,800 feet.
8.Degree of protection: NEMA 1 (IP20).
9.All products shall have corrosion protection.
I.All major assemblies and sub-assemblies, circuit boards, and devices shall be identified
using permanent labels or markings indicating:
1.Modules product type such as analog or digital.
2.Modules catalog number.
3.Modules major revision number.
4.Modules minor revision number.
5.Module manufacturer vendor.
6.Module serial number.
J.All necessary cables shall be included. All cables and connectors shall be as specified by the
manufacturer. Cables shall be assembled and installed per the manufacturer
recommendations.
K.All types of input/output modules shall be color coded and titled with a distinctive label.
2.02MANUFACTURERS
A.Provide all PLCs and HMI software from a single manufacturer. If the PLC manufacturer has
authorized third-party vendors to provide modules that are compatible with their
platforms, then products manufactured by these authorized third-party vendors will be
acceptable.
B.Provide the PLC system by one of the following; no others approved:
1.The Programmable Logic Controller (PLC) system shall be the CompactLogix PLC
systems manufactured by Rockwell Automation (Allen-Bradley) only.
C.Processor and associated I/O shall be selected as required to meet the minimum memory
and I/O requirements of the final control programming with a minimum of 30% memory
and a minimum of 30% spare I/O reserved for program and facility expansion.
D.The following table lists Approved PLC components. There will be NO SUBSTITUTIONS.
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Description Manufacturer Part Number
Power Supply Module Allen Bradley CompactLogix PLC 24-volt DC power supplies
CPU (Processor) Allen Bradley 5069-L310ER
Description: Controller, CompactLogix 5380, 1MB
User Memory, 8 I/O, 24 EtherNet/IP Devices
5069-L320ER
Description: Controller, CompactLogix 5380, 2MB
User Memory, 16 I/O, 40 Ethernet/IP Devices
5069-L330ER
Description: Controller, CompactLogix 5380, 3MB
User Memory, 31 I/O, 60 Ethernet/IP Devices
5069-L340ER
Description: Controller, CompactLogix 5380, 4MB
User Memory, 31 I/O, 90 Ethernet/IP Devices
(Minimum CPU shall be sized by CONTRACTOR and
proposed to OWNER/ENGINEER for final approval)
16 Channel Digital Input Module Allen Bradley CompactLogix 5069IB16
16 Channel Digital Output Module Allen Bradley CompactLogix 5069-OB16
8 Channel Analog Input Module Allen Bradley CompactLogix 5069-IF8
8 Channel Analog Output Module Allen Bradley CompactLogix 5069-OF8
E.The following table lists Approved PLC accessories.
Description Manufacturer Part Number
Modbus/RS232/RS485 to Ethernet IP Red Lion DSPLE000 Station
converter (Gateway Unit)
F.The listing of specific manufacturers above does not imply acceptance of their products
that do not meet the specified ratings, features and functions.
G.Each Gateway Unit supplied for this project shall be with a memory card.
H.All additional appurtenances shall be provided to support a fully functional system.
2.03PROCESSOR
A.The CPU shall be, at a minimum, a 32-bit microprocessor that provides system timing and is
responsible for scheduling I/O updates, with no user programming required to ensure
discrete or analog update. It shall execute user logic programs, communicate with
intelligent I/O modules, and perform on-line diagnostics. The CPU shall consist of a single
module that solves application logic, stores the application program, stores numerical
values related to the application processes and logic, and interfaces to the I/O.
B.The CPU shall sample all the discrete and analog inputs and outputs including internal coils
and registers, and service special function modules every scan. The CPU shall process the
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I/O with user program(s) stored in memory, then control the outputs based on the results
of the logic operation.
C.Supply the CPU with a battery-backed time of day clock and calendar.
D.The CPU family shall allow for user program transportability from one CPU model to
another.
E.Diagnostics
1.The CPU shall perform on-line diagnostics that monitor the internal operation of the
PLC. If a failure is detected, the CPU shall initiate system shutdown. The following, at a
minimum, shall be monitored: Memory failure, memory battery low, and general fault,
communications port failure, scan time over run, I/O failure, and analog or special
function I/O module failure.
2.All diagnostic information shall be accessible to the host communications interfaces
and to the PLC program.
3.The PLC shall have indicators and onboard status area to indicate the following
conditions:
a.CPU run.
b.CPU error or fault.
c.I/O failure or configuration fault.
d.Battery good.
e.Communications indicator.
F.Memory
1.The user program and data shall be contained in non-volatile battery backed memory.
CPUs shall be provided with maximum available memory for logic programming
storage, including on-board CPU memory and provision of available separate memory
card modules.
2.Type: CMOS RAM program memory.
3.Memory Backup: Lithium battery backup or flash memory system capable of retaining
all memory for a minimum of three months.
4.Backup Battery: The backup battery shall be capable of being replaced without
disrupting memory integrity. Provide a visual indication of low battery voltage and a
low battery alarm contact.
5.Flash Memory: Upon power loss, the PLC shall transfer internal memory to flash
memory before the PLC powers down.
6.The operator should be able to backup volatile memory, including data and program
logic onto a personal computer storage disk.
7.The operating system shall be contained in non-volatile firmware. The memory
containing the operating system shall be field updateable via a separate update tool.
G.Programming Environment
1.Programming port: The PLC shall utilize a serial USB or Ethernet port for programming.
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2.On-Line programming: Application programs may be modified or stored while the CPU
is running with minimal impact on the scan time.
3.Online programming including runtime editing.
4.IEC 61131-3 programming languages supported: Ladder logic, function block,
sequential function chart, and structure text.
5.Supply all hardware and software necessary to program the CPU in these languages.
H.Communication Ports
1.The CPU shall be expandable and supplied with additional modules to support the
required communication interfaces.
I.Remote I/O Communications
1.The CPU shall be capable of communicating with up to 12 remote base locations at a
combined distance of 2500 feet. The CPU shall automatically sample and update all
local and remote I/O modules each scan cycle of the CPU.
2.The communication link between the CPU and any RIO chassis shall be as
recommended by the PLC manufacturer. For racks located on a link of less than 2500
cable feet, the speed of the communications link shall be greater than 230 K baud with
RIO scan rate of less than 5 milliseconds per RIO.
3.Diagnostic and equipment status information shall be available from each RIO.
4.It shall be possible to communicate with remote I/O racks or other PLCs via fiber optic
cable.
5.The remote I/O system shall have available a remote input/output arrangement
capable of operation at locations physically separated from the PLC CPU by up to 5,000
feet as detailed on the drawings.
6.Communication with the remote I/O arrangement shall be through cable as
recommended by the PLC manufacturer and provided by the PLC system supplier
under this specification section.
2.04POWER SUPPLIES
A.The PLC shall have chassis-mounted power supplies to power the chassis backplane, and
provide power for the processor and applicable modules. Power supplies shall have a
clearly visible LED to indicate that the incoming power is acceptable and the output voltage
is present. Power supplies shall feature over-current and over-voltage protection and
should be designed to operate in most industrial environments without the need for
isolation transformers.
B.Power supplies shall be sized to accommodate the anticipated load plus 30 percent.
C.DC power supplies shall be capable of handling ripple up to 2.4V peak to peak.
D.AC Line Voltage rating of 85 to 265 VAC, 47-63 Hz.
E.The power supplies shall allow for brown outs of at least 1/2 of a cycle, a harmonic rate of
10 percent, and will sustain continuous operation through momentary interruptions of AC
line voltage of 10 ms or less.
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F.Automatically shut down the Programmable Controller system whenever its output power
is detected as exceeding 125 percent of its rated power.
G.Provide surge protection, isolation, and outage carry-over up to two cycles of the AC line.
2.05PLC/RIO CHASSIS
A.All system and signal power to the CPU and support modules shall be distributed on the
backplane. No interconnecting wiring between these modules via plug-terminated jumpers
shall be acceptable.
B.All system modules, main and expansion chassis shall be designed to provide for free air
flow convection cooling. No internal fans or other means of cooling, except heat sinks, shall
be permitted.
C.All system modules including the processor shall be removable from the chassis or inserted
in to the chassis while power is being supplied to the chassis without faulting the processor
or damaging the modules.
D.Modules shall be designed to plug into a chassis and to be keyed to allow installation in
only one direction. The design must prohibit upside down insertion of the modules as well
as safeguard against the insertion of a module into the wrong slot or chassis via an
electronic method for identifying a module. Electronic keying shall perform an electronic
check to insure that the physical module is consistent with what was configured.
2.06DISCRETE I/O MODULES
A.General
1.For existing system replacements, selection of discrete input and output modules
types shall be based on maintaining functionality and connection to existing PLC/RIO
signals. For new systems, selection of discrete input and output module types shall be
per OWNER/ENGINEER requirements included in this specification Section.
2.Digital input and output modules shall provide ON/OFF detection and actuation.
3.The I/O count and type shall be as required to implement the functions specified plus
an allowance for active spares, as noted below.
4.Modules shall be designed to be Hot-Swappable, or installed or removed while chassis
power is applied and PLC continues to execute.
5.Modules shall have indicators to display the status of communication, module health
and input/output devices.
6.Each module shall have the following status indicators:
a.The On/Off state of the field device.
b.The module’s communication status.
7.I/O modules shall contain a maximum of 16 points per module.
8.Discrete output modules shall be configurable to hold last value, turn on, or turn off
upon failure or fault state.
B.Discrete Module Specifications
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1.Digital Input
a.16 digital input points (maximum).
b.24 VDC Sink/Source.
c.Opto-isolated input points.
d.Time-lagged messages.
e.On-board communications and functional firmware.
f.On-board voltage regulation.
g.LEDs for power, receive data, transmit data, input status, and CPU fault.
h.Surge protected (non-destructive).
i.Removable without disturbing field wiring.
j.No on-board adjustments, switches or straps (self-configuring).
2.Digital Output
a.16 outputs (maximum).
b.24 VDC Source.
c.Opto-isolated input/output points.
d.Outputs may be solid-state or mechanical relay.
e.Time-tagged messages.
f.On-board communications and functional firmware.
g.On-board voltage regulation.
h.LEDs for power, receive data, transmit data, input status, and CPU fault.
i.Surge protected (non-destructive).
j.Removable without disturbing field wiring.
k.No on-board adjustments, switches or straps (self-configuring).
l.Keyed to prevent damage.
2.07ANALOG I/O MODULES
A.General
1.For existing system replacements, selection of analog input and output modules types
shall be based on maintaining functionality and connection to existing PLC/RIO signals.
For new systems, selection of analog input and output module types shall be per
OWNER/ENGINEER requirements included in this Specification Section.
2.Analog input modules shall convert an analog signal that is connected to the module’s
screw terminals into a digital value. The digital value representing the magnitude of
the analog signal shall be transmitted on the backplane. Analog output modules shall
convert a digital value that is delivered to the module via the backplane into an analog
signal on the module’s screw terminals.
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3.The I/O count and type shall be as required to implement the functions specified plus
an allowance for active spares, as noted below.
4.Modules shall be designed to be Hot-Swappable, or installed or removed while chassis
power is applied and PLC continues to execute.
5.Modules shall have indicators to display the status of communication, module health
and input/output devices. Each analog module shall provide both hardware and
software indication when a module fault has occurred. Each module shall have an LED
fault indicator and the programming software shall display the fault information.
6.Analog modules shall be software configurable through the I/O configuration portion
of the programming software.
7.The following status shall be capable of being examined in programming logic:
a.Module Fault Word – Provides fault summary reporting.
b.Channel Fault Word – Provides under-range, over-range and communications
fault reporting.
c.Channel Status Words – Provides individual channel under-range and over-range
fault reporting for process alarm, rate alarms and calibration faults.
8.The 24 VDC power for analog instrument loops shall be provided as a part of the
system. The 24 VDC power supply shall be derived from the 120 VAC input power
circuit to the PLC. The field side of the 24 VDC power sources(s) shall have individual or
grouped (of logically associated circuits) fusing and be provided with a readily visible,
labeled blown fuse indicator.
B.Analog Module Specifications
1.Analog Input
a.Eight single-ended analog input points (maximum).
b.Analog inputs will be 4-20 mA and use Shielded Cable.
c.16-bit Resolution.
d.24 VDC isolated power source.
e.Time-tagged messages.
f.On-board communications and functional firmware.
g.On-board voltage regulation.
h.LEDs for power, receive data, transmit data, CPU failure, and digital input status.
i.Surge protected (non-destructive).
j.Removable without disturbing field wiring.
k.No on-board adjustments, switches, or straps (self-configuring).
l.Keyed to prevent damage.
2.Analog Output
a.Eight analog output points (maximum).
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b.12-bit digital-to-analog converter.
c.Time-tagged messages.
d.On-board communications and functional firmware.
e.On-board voltage regulation.
f.LEDs for power, receive data, transmit data, and CPU failure.
g.Surge protected (non-destructive).
h.Removable without disturbing field wiring.
i.No on-board adjustments, switches or straps (self-configuring).
j.Keyed to prevent damage.
2.08COMMUNICATION INTERFACES
A.The PLC will be capable of the following communication protocols as shown on the
drawings:
1.10BASE-T/100BASE-TX Ethernet communication.
2.Asynchronous serial link capable of communicating up to 19.2Kbps.
B.When required, provide a Communications Interface Module mounted in the chassis or the
equivalent port directly on the CPU.
2.09PLC SOFTWARE
A.The PCSI shall utilize its own PLC configuration and application development software to
perform the work associated with this project. One new PLC software development
package and associated license and activation shall be procured for the OWNER on this
project.
B.The software package shall allow on-line/off-line program development, annotation,
monitoring, debugging, uploading, and downloading of programs to the PLCs.
C.All required hardware (including cables, cable adapters, etc.) for connection to PLCs shall be
furnished.
D.All software licenses required to achieve the functionality described in the Specifications
shall be provided.
E.The software provided shall be capable of the IEC 61131-3 function block.
1.Function Block Diagram Programming.
2.Ladder Logic
F.In addition to the above editors, an add-on instruction editor shall work with any of the
above-mentioned editors to create custom reusable function blocks. This software shall
allow any of the derived function blocks to be modified on-line.
G.The software shall be Microsoft Windows-based and run on the supplied computers.
H.The software shall include a security feature to prevent unauthorized personnel from
modifying and downloading the programs.
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I.The software shall include an I/O simulator that allows the PLC application load program to
be tested on a PC with simulated analog and digital inputs and outputs, allowing I/O testing
and debugging to be performed in a safe, isolated environment without the need for
running the PLC CPU and process I/O boards.
J.The PLC programming software shall be Rockwell Automation Studio5000 Logix Designer
with all associated required communications and configuration packages. PLC programming
shall use PlantPAx Object Library. The CONTRACTOR shall coordinate software version and
Object library version with OWNER’s I.T. Department prior to procurement.
2.10OPERATOR INTERFACE TERMINALS (OIT)
A.Operator Interface Terminals shall have viewable screen sizes of 15 inches.
B.Screen Type: Operator Interface Terminals will use a color TFT screen The screen shall have
an 1024x768 pixel (XGA) resolution, 18-bit color graphics, with a backlighting service life of
50,000 hours of continual usage. There shall be an embedded analog resistive touch screen
with actuation rating of 1 million presses, and operating force of 100 grams.
C.Primary Memory: The Operator Interface Terminals shall have a 32Mb flash EPROM
memory and a Compact Flash expansion memory slot. A Compact Flash card shall be
provided with each OIT supplied.
D.RAM: The Operator Terminal shall be supplied with lithium batteries to back up 512Kb
SRAM.
E.Communications:
1.The Operator Interface Terminals shall have an RJ-45 dedicated to serial
communications. The RJ-45 port shall support RS485 communications.
2.One (1) USB 2.0 high speed host port (type A) connector shall be provided that
supports removal flash drives for storage and one (1) high speed 1.0 device port (type
B) that supports connection to host computer.
3.Provide an integral Ethernet port dedicated to 10/100BASE-T Ethernet TCP/IP
communications.
4.Operator Interface Terminals relying on the same port for communications and
downloading shall not be acceptable.
F.Software
1.The PCSI shall utilize its own OIT configuration and application development software
to perform the work associated with this project. One new OIT software development
package and associated license and activation shall be procured for the OWNER on this
project.
2.OIT programming shall use FactoryTalk View ME v13.00.00 and PlantPAx Object Library
v5.00.04. The CONTRACTOR shall coordinate software version with OWNER during
construction.
G.Manufacturer:
1.Allen-Bradley PANELVIEW PLUS 7 Touch Screen 2711P-T9W21D8S-B. The
CONTRACTOR shall coordinate the firmware version with OWNER’s I.T. Department
prior to procurement.
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2.No substitutions are allowed.
3.00EXECUTION
3.01GENERAL INSTALLATION
A.Maintain area free of dirt and dust during and after installation of programmable controller
products.
B.Anchor PLCs within enclosures as recommended by the PLC manufacturer.
C.Ventilation slots shall not be blocked or obstructed by any means.
D.Examine areas, surfaces, and substrates to receive PLCs for compliance with requirements,
installation tolerances, and other conditions affecting performance. Proceed with
installation only after unsatisfactory conditions have been corrected.
E.Install in accordance with manufacturer’s instructions.
F.Unload, unpack, and transport equipment to prevent damage or loss.
G.Replace damaged components as directed by ENGINEER.
3.02PANEL LAYOUT
A.Coordinate size and configuration of enclosure to meet project requirements. Drawings
indicate maximum dimensions for PLCs, minimum clearances between PLCs, and adjacent
surfaces and other items.
B.Comply with indicated maximum dimensions and clearances, or with PLC vendor’s required
distances if they are greater than the distances indicated.
C.Provide spacing around PLC as required by the PLC manufacturer to insure adequate
cooling. Ensure that the air surrounding the PLC has been conditioned to maintain the
required temperature and humidity range.
D.Wires entering and exiting PLC components shall be sized to comply with the PLC
manufacturer’s requirements. Doors on all components shall be able to be fully closed
when all the wires are installed.
E.For chassis-mounted PLCs, no wiring, wire ducts, or other devices shall obstruct the
removal of cards from the rack.
F.PLC lights, keys, communication ports, and memory card slots shall be accessible at all
times. Lights shall be visible at all times when enclosure door is opened.
G.Control panel designer shall provide independent line fuses or circuit breakers, per the PLC
manufacturer recommendation, for each power supply, input module, output module, and
other modules with separately derived power requirements.
H.Control panel designer shall insure that communication signals, 4-20 mA signals (including
those with embedded HART), are properly conditioned for the PLC and protected from all
sources of radiated energy or harmonics.
I.Each PLC (including all I/O) shall be powered from a UPS power conditioning system.
J.Where multiple mechanical components are provided for process redundancy, their field
connections to I/O modules shall be arranged such that the failure of a single module will
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not disable all mechanical components associated with the process redundancy (e.g., inputs
and outputs for redundancy device 1 shall reside on different modules than the inputs and
outputs for redundancy device 2, etc.), irrespective of the number of used points resulting
from this configuration.
K.Provide all required cables, cords, and connective devices for interface with other control
system components.
END OF SECTION
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SECTION 40 63 00A
ATTACHMENT A - PLC HARDWARE SCHEDULE
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NOTES
N
SITE
AIOCSECP1188RR
1
Resaca Lift Station PLC62XXX4121XX
2
Generator PLC (ATS/GEN)40XXX22
3
Master Blower PLC38XXX2131X
4
Blower PLC 121XXX1121X
5
Blower PLC 221XXX1121X
6
Blower PLC 321XXX1121X
7
Blower PLC 421XXX1121X
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40 66 00 PROCESS CONTROL SYSTEM - NETWORK EQUIPMENT
1.00GENERAL
1.01SCOPE OF WORK
A.This Section includes network equipment used in process control networks
including:
1.Network switches.
2.Media converters.
3.Patch panels and other data network hardware.
4.Related accessories.
B.The Process Control System Integrator (PCSI) shall furnish the labor and materials
required to install and bring into operation the control and data network, complete
as shown on the Drawings and specified herein.
C.Furnish and configure the network equipment as shown on the drawings. Minimum
sizing is based upon initial engineering design and needs to be confirmed prior to
equipment procurement. It is the responsibility of the Contractor or PCSI to design
and size the network systems. Contractor to coordinate with the City IT Department
for configuration of the new switches. City IT Department will program/configure all
existing network equipment to accommodate changes made on this project.
D.The network shall be capable of supporting communications between all servers,
operator workstations, PLCs, RTUs, and other communication devices as shown on
the system architecture block diagram(s). The PCSI shall furnish all necessary cables,
face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc.,
required for a complete and operational network. The system architecture
diagram(s) are for network understanding only. Some communication devices
maybe required for network operation, which may not be explicitly shown on the
Drawings. The system shall be designed to accommodate an increased bandwidth
equal to an additional 100 percent of network nodes.
E.The control and data network shall include all nodes on the network.
Communication between nodes may be via Ethernet, serial, field bus, or other
method as specified.
F.Network Panels to be supplied by the PCSI include the following:
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Panel Tag/ Panel Size
Enclosure Rating &
Facility/Area Make/Model
Type
Designation (HxWxD)
Resaca Electrical
Building
NEMA 12, Wall-
Mount, 15U, Clear
WAVENET Tempered Plexiglass
RESACA 31.5”24.8”x24.8”
CBTF-WM15U-SW Front Door, Shatter
Resistance Lockable
Door
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.Refer to Division 40, Section 40 67 00, Process Control System – Control Panels and
Components.
1.03SUBMITTAL REQUIREMENTS
A.Refer to Division 01 for general submittal requirements.
B.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
C.Operation and Maintenance Data: Provide literature detailing all custom configured
parameters and backup/restore procedures for each network component.
1.04REFERENCE STANDARDS
A.Institute of Electrical and Electronics Engineers (IEEE):
1.802.3 – Ethernet.
2.802.11 – Wireless LANs.
1.05DELIVERY, STORAGE, AND HANDLING
A.Deliver network components in packaging designed to prevent damage from static
electricity and physical damage.
B.Store network equipment according to manufacturer requirements. At a minimum,
store indoors in clean, dry space with uniform temperature to prevent
condensation. Protect network components from exposure to dirt, fumes, water,
corrosive substances, and physical damage. Also, protect from all forms of electrical
and magnetic energy that could reasonably cause damage.
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2.00PRODUCTS
2.01GENERAL
A.All cabling required to interconnect all components of the network system shall be
provided by the PCSI and/or Contractor.
B.The network equipment shall be suitable for installation at the location as shown on
the drawings.
2.02NETWORK SWITCH – BACKBONE – MANAGED INDUSTRIAL – DIN RAIL MOUNT
A. General 1. Provide Ethernet Managed Switches as shown in the Drawings and
specified herein.
2.Ethernet data rate: 10/100/1000 Mbps
3. Copper Ports: 24 x 10/100 BASE-T ports, minimum. Provide 1GB
where indicated.
4. Uplink: 1GB minimum. Provide SFP ports as required for connectivity
as specified and shown in the Drawings.
5.Industrial Rated, IEC/EN 61000-6-2
6.Operating Temperature: -10 to 60 degrees C (14...140 °F).
7. DIN-rail mounted
8. Provide Ethernet Managed Switches as shown in the Drawings and
specified herein.
B. Function 1. Input Power: 120 VAC or 24 VDC power supply.
2.Amperage: 2.5A
3.Power Supply: 120W Max
4. Firmware Type: LAN Base
5. IEEE 802.1, IEEE 802.3, SSH, SNMPv3, syslog, IGMP Snooping, IEEE
802.3ad Link Aggregation (LACP)
6. IPv4 static routing, Port-Security, 802.1x, QoS, IEEE 1588 PTP, SNMP
7.Fiber Uplinks: 4x 100/1000 FX or SFP ports, minimum.
8.Copper Ports: 24x 10/100/1000BASE-T ports, minimum.
9. Operating Temperature: 0 to 50 degrees C.
10.SNMP network management.
11.DHCP port allocation, HTTPS access, web-based configuration.
12. VLAN, 802.1q Trunking, QoS, IGMP snooping, IGMP filtering, port
level controls, IEEE 802.1d/w spanning tree protocol support.
13. Security: Access List, MAC address filtering, SSH protocol, DHCP
snooping, port security, aging control, Dynamic ARP.
14.Port mirroring, redundant network/ring coupling.
15. Support Ethernet/IP and Modbus/TCP protocols for device
management and monitoring.
C.Physical1.Enclosure: IP30 Metal case, DIN rail mount.
2. UL Listed.
D. Options/ 1. Provide SFP Modules as required to meet connectivity requirements.
Accessories
2. Provide memory card (if available)
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3. Provide Expansion Modules as required to meet connectivity
requirements.
4. Provide AC to DC power supply as required for connection of each
switch to available power circuit.
E.Manufacturer1.Moxa EDS-528E.
2.No others.
2.03NETWORK SWITCH – SPUR – MANAGED INDUSTRIAL – DIN RAIL MOUNT
A. General 1. Provide Ethernet Managed Switches as shown in the Drawings and
specified herein.
2. Ethernet data rate: 10/100/1000 Mbps
3. Copper Ports: 8 x 10/100 BASE-T ports, minimum. Provide 1GB where
indicated.
4. Uplink: 1GB minimum. Provide SFP ports as required for connectivity
as specified and shown in the Drawings.
5.Industrial Rated, IEC/EN 61000-6-2
6. Operating Temperature: -10 to 60 degrees C (14...140 °F).
7.DIN-rail mounted
8. Provide Ethernet Managed Switches as shown in the Drawings and
specified herein.
B.Function1.Input Power: 120 VAC or 24 VDC power supply.
2. Amperage: 2.5A
3.Power Supply: 120W Max
4.Firmware Type: LAN Base
5. IEEE 802.1, IEEE 802.3, SSH, SNMPv3, syslog, IGMP Snooping, IEEE
802.3ad Link Aggregation (LACP)
6.IPv4 static routing, Port-Security, 802.1x, QoS, IEEE 1588 PTP, SNMP
7. Fiber Uplinks: 2 x 100/1000 FX or SFP ports, minimum.
8.Copper Ports: 6x 10/100/1000BASE-T ports, minimum.
9.Operating Temperature: 0 to 50 degrees C.
10. SNMP network management.
11.DHCP port allocation, HTTPS access, web-based configuration.
12. VLAN, 802.1q Trunking, QoS, IGMP snooping, IGMP filtering, port
level controls, IEEE 802.1d/w spanning tree protocol support.
13. Security: Access List, MAC address filtering, SSH protocol, DHCP
snooping, port security, aging control, Dynamic ARP.
14. Port mirroring, redundant network/ring coupling.
15. Support Ethernet/IP and Modbus/TCP protocols for device
management and monitoring.
C. Physical 1. Enclosure: IP30 Metal case, DIN rail mount.
2.UL Listed.
D. Options/ 1. Provide SFP Modules as required to meet connectivity requirements.
Accessories
2.Provide memory card (if available)
3. Provide Expansion Modules as required to meet connectivity
requirements.
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4. Provide AC to DC power supply as required for connection of each
switch to available power circuit.
E.Manufacturer1.Moxa EDS-508A.
2. No others.
2.04FIBER OPTIC PATCH PANEL – WALL MOUNT
A. General 1. Provide wall mounting fiber optic patch panel as shown in the Drawings
and specified herein.
B. Function 1. Patch panels shall be suitable for single-mode systems operation. Patch
panels shall be suitable for ST connectors. The patch panels shall be sized
to handle the number of fibers as required. All fibers shall be terminated
in the patch panel.
C. Physical 1. Mounting Type: Wall-Mountable
2.Panels per Housing: 2
D. Options/ 1. All unused couplings shall have protective dust covers. All panels shall be
Accessoriesfurnished with locking doors
E. Manufacturer 1. CORNING WIC-02P.
2. LIGHTWAVE WAC Series
3.Approved Equal.
2.05FIBER OPTIC PATCH PANEL – RACK MOUNT
A. General 1. Provide rack mounting fiber optic patch panel as shown in the Drawings
and specified herein.
B. Function 1. Patch panels shall be suitable for single-mode systems operation. Patch
panels shall be suitable for ST connectors. The patch panels shall be sized
to handle the number of fibers as required. All fibers shall be terminated
in the patch panel.
C.Physical1.Mounting Type: Rack-Mountable
2. Panels per Housing: 2
D. Options/ 1. All unused couplings shall have protective dust covers. All panels shall be
Accessoriesfurnished with locking doors
E. Manufacturer 1. CORNING.
2.LIGHTWAVE RAC Series
3. Approved Equal.
2.06ETHERNET REMOTE I/O – DIN RAIL MOUNT
A. General 1. Provide ethernet remote I/O as shown in the Drawings and specified
herein.
B.Function1.Analog input channels: 2minimum
C.Physical1.Power: 24VDC
2.Industrial Protocol: Modbus TCP, Ethernet/IP
D. Options/ 1. Mounting Type: Din Rail-Mountable
Accessories
E. Manufacturer 1. MOXA IO Logik E1200 Series
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2.07CABLING AND CONNECTORS
A.Ethernet 10/100/1000 BASE-T/TX Cable
1.The unshielded twisted pair cable shall be designed for use with a high speed
(10/100/1000 Mbps) Ethernet 10/100/1000 BASE-T/TX communications
network.
2.The twisted pair cable shall have a nominal impedance 100 Ohms at one MHz,
a maximum attenuation of 8 dB per 1000 feet at one MHz. The twisted pair
cable must have frequency tested up to 600 MHz or more.
3.Meet the requirements of the ANSI/TIA-568-D specification for Category 5e
(CAT5e), Unshielded Twisted Pair (UTP) cable.
4.The twisted pair cable shall be plenum rated, blue in color, and shall have a
minimum of four 24 AWG solid copper conductor pairs.
5.All 10/100/1000 BASE-T/TX (RJ-45) terminations on the twisted pair cable shall
be done in a professional and workmanlike manner. Terminations shall
provide for proper strain relief on the cable jacket. Strain relief on the wire
and/or wire insulation shall not be acceptable.
B.RIO Data Highway Cable
1.The RIO data highway cable shall be plenum rated cable of the type as
recommended by the PLC manufacturer.
2.All terminations shall be done in a professional and workmanlike manner.
Terminations shall provide for proper strain relief on the cable jacket. Strain
relief on the wire and/or wire insulation shall not be acceptable.
3.00EXECUTION
3.01GENERAL INSTALLATION
A.Install and connect the equipment in accordance with the manufacturer's
instructions.
B.Install the fiber optic patch panel and the Ethernet switch.
C.Connect the new fiber optic patch panel to the existing fiber optic patch panel as
shown in the drawings.
3.02INSTALLATION AND CONFIGURATION
A.Configure Ethernet switch network for a complete, functioning plant control system
as indicated on the Drawings and as specified herein:
1.Refer to SCADA System Architecture diagram for all new network connections.
2.All PLC peer-to-peer communications, remote I/O for both the SCADA OIT
network shall be over a 1 Gbps network.
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3.Provide configuration for all managed Ethernet switches and other
components, including but not limited to VLAN (Virtual Local Area Network),
additional Plant PLC communication cards, and separate managed Ethernet
switches as required, such that there is isolation of the following networks:
a.Field and PLC I/O network: This includes the connections between the
Plant PLC and:
1).Plant PLC expansion racks.
2).Plant PLC remote I/O (RIO) racks.
3).Field Networks.
4).HMI(s) part of a Plant PLC.
5).Vendor-furnished Ethernet network components.
b.Process Control network: This includes the connections between the
various Process Control equipment including but not limited to servers,
workstations, PLCs, and printers.
4.The process floor managed Ethernet switches for the process control network
shall be configured and programmed for rapid fail over protection.
B.Managed Ethernet Switches
1.Configure switches to prevent broadcast storms.
2.Installations utilizing Rockwell PLCs and multicast messaging shall employ
IGMP snooping router ports.
3.Install Velcro wrap on all cable bundles within the network rack/enclosure.
4.All cables and equipment shall be installed in strict conformance with the
manufacturer’s recommendations:
a.Cables shall be installed avoiding sharp bends.
b.Install cable using lubricant designed for cable pulling.
c.Cable ties or other cable supports shall be installed without crimping the
LAN cables.
d.Install LAN cables without splices.
e.Installed bend radii shall not exceed 4 times the cable diameter.
f.Terminate all pairs at the jack and the patch panel.
5.Install cables a minimum of 40 inches away from electrical motors and
transformers.
6.Install cables a minimum of 12 inches away from fluorescent lighting.
7.Individual pairs will be untwisted less than 1/2-inch at termination points.
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3.03ETHERNET CABLE INSTALLATION
A.The bend radius for cable shall not be less than the manufacturer’s recommended
minimum bend radius.
B.As a minimum, provide a two (2) foot service loop of all cables within all enclosures.
C.The cable should not come in contact with any water or chemicals (ex. paint,
lubricants), or be exposed to any high humidity during or after installation.
D.Avoid any cable kinks and maintain proper bend radius control during cabling
pulling. If any kinks should occur, kinked cable should be removed and replaced.
3.04CABLE ACCEPTANCE TESTING - GENERAL
A.This Section specifies the inspection, test, and acceptance requirements for the
structured cabling of the Local Area network.
B.Provide test equipment required to conduct acceptance tests.
C.Submit acceptance documentation as defined in this Section.
D.All of the installed cabling must be tested and successfully pass test criteria.
E.Standards referenced in this Section include:
1.ANSI/TIA-568-D: Telecommunications Cabling Standard. Standards referenced
within the ANSI/TIA-568-D, where applicable, constitute standard provisions of
this Specification.
F.Visually inspect cables, cable reels, and shipping cartons to detect possible cable
damage incurred during shipping and transport. Visibly damaged goods are to be
returned to the Supplier and replaced at no additional cost to the OWNER.
G.The OWNER reserves the right to conduct, using the CONTRACTOR’s equipment and
labor, a re-test to confirm documented results. Any failed cabling shall be re-tested
and restored to a passing condition.
H.Acceptance shall be subject to completion of Work, successful post-installation
testing which yields 100% PASS rating, and receipt of full documentation as
specified in the Contract Documents.
I.Cable Test Results Manual
1.Submit test reports in electronic format. Handwritten and scanned test reports
are not acceptable. Submit electronic files in PDF format.
2.The CONTRACTOR must sign the submitted test results, certifying that the test
results are accurate and complete.
3.The Consultant and OWNER will review the submitted test result for
conformance with the design as specified.
J.CAT5e UTP Horizontal twisted pair cable shall meet or exceed the permanent link,
performance requirements specified in ANSI/TIA-568-D.2 for Category 5e,
Unshielded Twisted Pair (UTP).
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K.Test Equipment. Test equipment shall meet the following minimum criteria:
1.All test equipment of a given type shall be from the same manufacturer, and
have compatible electronic results output. Acceptable test equipment
manufacturers are Fluke Corporation, Hewlett-Packard Development
Company, L.P (Hewlett Packard), or MicroTest Inc. (MicroTest).
2.Test adapters must be approved by the manufacturer of the test equipment.
Adapters from other sources are not acceptable.
3.Baseline accuracy of the test equipment must exceed TIA Level III, as indicated
by independent laboratory testing.
4.Test equipment must be capable of certifying Category 5e STP to ANSI/TIA-
568-C.2-1 standards.
5.Test equipment must have a dynamic range of at least 200 dB to minimize
measurement uncertainty.
6.Test equipment must be capable of storing full frequency sweep data for tests.
7.Test equipment must include S-Band time domain diagnostics for NEXT and
return loss (TDNXT and TDRL) for accurate and efficient troubleshooting.
8.Test equipment must be capable of running Wire Map, Length, Insertion Loss,
NEXT Loss, PS NEXT Loss, ACR-F Loss, PS ACR-F Loss, Return Loss, Propagation
Delay and Delay Skew tests. Individual tests increase productivity when
diagnosing faults.
9.Test equipment must make swept frequency measurements in compliance
with latest ANSI/TIA-568 standards.
10.The measurement reference plane of the test equipment shall start
immediately at the output of the test equipment interface connector. There
shall not be a time domain dead zone of any distance that excludes any part of
the link from the measurement.
L.Documentation. At a minimum, test reports shall include the following information
for each UTP/STP Ethernet cabling element tested:
1.Wiremap results that indicate the cabling has no shorts, opens, mis-wires,
split, reversed, or crossed pairs, and end-to-end connectivity is achieved.
2.Attenuation, NEXT, PSNEXT, Return Loss, ACR-F, and PS ACR-F data that
indicate the worst-case result, the frequency at which it occurs, the limit at
that point, and the margin. These tests shall be performed in a swept-
frequency manner from 1 MHz to highest relevant frequency, using a swept-
frequency interval that is consistent with TIA and ISO requirements.
Information shall be provided for pairs or pair combinations and in both
directions when required by the appropriate standards.
3.Length (in feet), propagation delay, and delay skew relative to the relevant
limit.
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4.Any individual test that fails the relevant performance specification shall be
marked as a FAIL.
5.Cable manufacturer, cable model number/type, and NVP.
6.Tester, manufacturer, model, serial number, hardware version, and software
version.
7.Circuit ID number (Cable Tag Id).
8.Test criteria used.
9.Overall pass/fail indication.
10.Date and Time of test.
3.05LABELING
A.All cables and terminations shall be labeled with cable designations as specified in
Division 26 Section, Electrical Identification.
B.Each data port shall be individually labeled with its patch panel/switch port ID:
1.Labeling must be printed; no handwritten labels will be allowed.
C.At the completion of the wiring installation, provide the following documentation:
1.A plan-view of the premise(s) showing the jack numbering scheme.
2.A printed certification report for the entire wiring installation showing
compliance with all EIA/TIA specifications for data cable.
D.Reports such as those generated by Fluke DSP cable certification equipment meet
this requirement.
E.Each device with a unique IP address shall be individually labeled with its IP address.
The labeling must be printed; handwritten labels will not be allowed.
3.06DEMONSTRATION AND TRAINING
A.As specified in Division 40, Section 40 61 26, Process Control System – Training.
B.After completion of the cable system tests and before placing the system in
operation, power up all devices installed on the LAN and verify communication
between the devices.
C.Verify that all equipment is operable on the network simultaneously. Confirm that
all network device communications settings are properly configured.
FOE!PG!TFDUJPO!
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40 67 00 PROCESS CONTROL SYSTEM – CONTROL PANELS AND COMPONENTS
1.00GENERAL
1.01SCOPE OF WORK
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.This specification is for local control panel and also panel components required for pre-
wiring the new PLC modules provided by the PCSI within this project.
C.All new panel components shall match existing equipment makes and models wherever
possible, so that system additions can be most easily integrated with respect to operation
and maintenance training, spare parts inventory, and service contracts. Even when exact
matches are not possible, equipment furnished must be fully compatible with the existing
system.
D.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,
PCSI, and ASP to design and size all panels that they will supply:
1.Size panels to provide space for all equipment, wiring, terminations, and other items
inside and outside of the panel, including space for future build out.
2.Panel sizes that substantially deviate (within six inches in any dimension) from the
sizes indicated on the Drawings must be approved by the Engineer.
3.Maximum panel depth: 30 inches, unless otherwise indicated.
E.Structural Design:
1.Completed and installed panel work shall safely withstand seismic requirements at the
project site, as specified in Division 01. Enclosures and internal equipment shall be
braced to prevent damage from specified forces.
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
2.00
2.01SUBMITTAL REQUIREMENTS
A.Refer to Division 01 for general submittal requirements.
B.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
2.02REFERENCE STANDARDS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.Underwriters Laboratories Inc. (UL):
1.508C – Standard for Industrial Control Equipment.
2.1283 – Standard for Electromagnetic Interference Filters.
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3.1449 – Standard for Surge Protective Devices.
2.03QUALITY ASSURANCE
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.Assemble panels, enclosures, rack systems, 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.
3.00DELIVERY, STORAGE, AND HANDLING
3.01 GENERAL
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
4.00PRODUCTS
4.01GENERAL
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
4.02LIGHTNING/SURGE PROTECTION
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
4.03CONTROL PANEL GENERAL REQUIREMENTS
A.The dimensions within this section and on the drawings are for general reference only.
Ensure that final enclosure sizing and panel arrangements accommodate all required
equipment for a fully integrated and operational system, as specified herein and in the
Drawings.
B.Each control panel and terminal cabinet shall bear the UL label. The UL label shall apply to
the enclosure, specific equipment supplied with the enclosure, and installation and wiring
of the equipment within and on the enclosure. If required for UL labeling, provide ground
fault protective devices, isolation transformers, fuses, and any other equipment necessary
to achieve compliance with UL 508 requirement.
C.All panel doors shall have a lock installed on the door handle or a hasp and staple for
padlocking. Locks for all panels provided under this Contract shall be keyed alike. Provide
door security/interlock switches as specified in this section.
D.The devices designated for rear-of-panel mounting shall be arranged within the panel
according to respective panel drawings and in a manner to allow for ease of maintenance
and adjustment. Heat generating devices such as power supplies shall be located at or near
the top of the panel.
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E.The panels shall be completely fabricated, instruments and devices installed, and wired at
the PCSI's facility.
F.All components shall be mounted in a manner that shall permit servicing, adjustment,
testing, and removal without disconnecting, moving, or removing any other component.
Components mounted on the inside of panels shall be mounted on removable plates and
not directly to the enclosure. Mounting shall be rigid and stable, unless shock mounting is
required otherwise by the manufacturer, to protect equipment from vibration.
G.Component mounting shall be oriented in accordance with manufacturer’s
recommendations. The internal components shall be identified with suitable plastic or
metal engraved nametags mounted adjacent to (not on) each component, identifying the
component in accordance with the drawing, specifications, and PCSI's data.
H.All exterior panel-mounted equipment shall be installed with suitable gaskets, faceplates,
etc. required to maintain the NEMA rating of the panel.
I.Provide nameplates as specified in this section.
J.Mounting Elevations:
1.ISA Recommended Practice RP60.3 shall be used as a guide in layout and arrangement
of panels and panel-mounted components. Dimensions shall account for all
housekeeping pads that panels will sit on once installed.
2.Centerline of indicators and controllers shall be located no lower than 48 inches or
higher than 66 inches above the floor or grade level on a panel face.
3.Centerline of lights, selector switches, and pushbuttons shall be located no lower than
32 inches or higher than 70 inches above the floor or grade level on a panel face.
4.Tops of annunciators shall be located no higher than 86 inches above the floor or
grade level on a panel face.
5.Installation of panel components shall conform to component manufacturers'
guidelines.
4.04PANEL MATERIALS AND CONSTRUCTION
A.Structure and Enclosure:
1.Panels shall be of continuous welded-steel or FRP construction, as shown on the Panel
Schedule in PART 1 of this section. For panels larger than four feet, provide angle
stiffeners, as required, on the back of the panel face to prevent panel deflection under
instrument loading or operation. Internally, the panels shall be supplied with a
structural framework for instrument support purposes and panel bracing. The internal
framework shall permit panel lifting without racking or distortion. Provide removable
lifting rings designed to facilitate simple, safe rigging and lifting of the control panels
during installation.
2.Each panel shall be provided with full height, fully gasketed access doors where
shown. Doors shall be provided with a three-point stainless steel latch and heavy duty
stainless steel locking handle. Panel access doors shall be provided with full length,
continuous, piano-type stainless steel hinges and stainless steel pins. Front access
doors with mounted instruments or control devices shall be of sufficient width to
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permit door opening without interference from rear projection of flush-mounted
instruments.
3.The panels, including component parts, shall be free from sharp edges and welding
flaws. Wiring shall be free from kinks and sharp bends and be routed for easy access to
other components for maintenance and inspection purposes.
4.The panel shall be suitable for top and bottom conduit entry, as required by the
Electrical Drawings. For top-mounted conduit entry, the panel top shall be provided
with nominal one foot, square, removable access plates, which may be drilled to
accommodate conduit and cable penetrations. All conduit and cable penetrations shall
be provided with ground bushings, hubs, gasketed locknuts, and other accessories as
required to maintain the NEMA rating of the panel and electrical rating of the conduit
system.
B.All panels in indoor, dry, non-corrosive environments shall be NEMA 12, unless otherwise
noted. All panels in outdoor, wet, and non-chemically corrosive environments shall be
NEMA 4, unless otherwise noted. Panels in chemically corrosive environments shall be
NEMA 4X, unless otherwise noted. All panels located in a hazardous location shall be rated
for the type of hazard (e.g., NEMA 7 for Class 1, Division 1).
C.Freestanding and Floor-Mounted Vertical Panels:
1.Freestanding and floor-mounted vertical panels shall meet the NEMA classification, as
shown on the drawings or specified herein. The panels shall be constructed of 12
gauge sheet steel, suitably braced internally for structural rigidity and strength. All
NEMA 4X rated panels shall be constructed of Type 316 stainless steel, unless
otherwise noted. Front panels or panels containing instruments shall be not less than
10 gauge, stretcher leveled sheet steel, reinforced to prevent warping or distortion.
D.Wall and Unistrut Mounted Panels:
1.All wall and unistrut-mounted panels shall meet the NEMA classification, as shown on
the drawings or specified herein. The panels shall be constructed of not less than USS
14 gauge steel, suitably braced internally for structural rigidity and strength. All NEMA
4X rated wall mounted panels shall be constructed of Type 316 stainless steel, unless
otherwise noted.
E.Finish Requirements:
1.All sections shall be descaled, degreased, filled, ground and finished. Enclosures
fabricated of steel shall be finished with two rust resistant, phosphate prime coats and
two coats of enamel, polyurethane, or lacquer finish, which shall be applied by either
the hot air spray or conventional cold spray method.
2.The panels shall have edges ground smooth and be sandblasted, then cleaned with a
solvent. Surface voids shall be filled and ground smooth.
3.Immediately after cleaning, one coat of a rust-inhibiting primer shall be applied inside
and outside, followed by an intermediate exterior, and top coat of a two-component
type epoxy enamel. A final sanding shall be applied to the intermediate exterior coat
before top coating.
4.Apply a minimum of two coats of flat white lacquer on the panel interior after priming.
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5.Unless otherwise noted, the finish exterior colors shall be ANSI 61 gray with a textured
finish. Enclosures that will be installed outdoors shall have a painted white exterior
finish.
F.Where required on the Panel Schedule, a folding shelf shall be provided on the inside of the
door on all freestanding and floor-mounted panels as specified herein.
4.05ENVIRONMENTAL CONTROL
A.All panels shall be provided with louvers, sun shields, heat sinks, forced air ventilation, or
air conditioning units, as required, to prevent temperature buildup inside of panel. The
internal temperature of all panels shall be regulated to a range of 45 to 104 degrees F
under all conditions. Under no circumstances shall the panel cooling or heating equipment
compromise the NEMA rating of the panel.
B.PCSI shall submit heat dissipation calculations for every control panel.
C.Except for panels mounted with their backs directly adjacent to a wall, louvers shall be on
the rear of the panels, top and bottom, and shall be stamped sheet metal construction.
D.For panels mounted with their backs directly adjacent to a wall, louvers shall be on the
sides.
E.Forced air ventilation fans, where used, shall provide a positive internal pressure within the
panel, and be provided with washable or replaceable filters. Fan motors shall operate on
120-volt, 60-Hz power.
F.For panels with internal heat that cannot be adequately dissipated with natural convection
and heat sinks or forced air ventilation, an air conditioner shall be provided.
G.Where required on the panel schedule, provide custom-fabricated sun shields for all
outdoor panels, as specified herein. Outdoor panels shall be painted white and satisfy all
other Owner panel fabrication and installation standards.
H.All outdoor enclosures and enclosures located in unheated areas indoors or in areas subject
to humidity and moisture shall be provided with an integral heater, fan, and adjustable
thermostat to reduce condensation and maintain the minimum internal panel temperature.
Mount the unit near the bottom of the enclosure with discharge away from heat-sensitive
equipment.
4.06CONTROL PANEL - INTERNAL CONSTRUCTION
A.Internal Electrical Wiring:
1.All interconnecting wiring shall be stranded type MTW, have 600V insulation, and be
rated for not less than 90 degrees Celsius. Wiring for systems operating at voltages in
excess of 120 VAC shall be segregated from other panel wiring, either in a separate
section of a multi-section panel or behind a removable Plexiglas or similar dielectric
barrier. Panel layout shall be developed such that technicians have complete access to
120 VAC and lower voltage wiring systems without direct exposure to higher voltages.
2.Power distribution wiring on the line side of fuses or breakers shall be 12 AWG, at a
minimum. Control wiring on the secondary side of fuses shall be 16 AWG, at a
minimum. Electronic analog circuits shall utilize 18 AWG shielded, twisted pair, cable
insulated for not less than 600 volts.
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3.Power and low voltage DC wiring systems shall be routed in separate wireways.
Crossing of different system wires shall be at right angles. Different system wires
routed parallel to each other shall be separated by at least 6 inches. Different wiring
systems shall terminate on separate terminal blocks. Wiring troughs shall not be filled
to more than 60 percent visible fill.
4.Terminations:
a.All wiring shall terminate onto single-tier terminal blocks, where each terminal is
uniquely and sequentially numbered. Direct wiring between field equipment and
panel components is not acceptable.
b.Terminal blocks shall be as specified herein. Multi-level terminal blocks or strips
are not acceptable.
c.Terminal blocks shall be arranged in vertical rows and separated into groups
(power, AC control, DC signal). Each group of terminal blocks shall have a
minimum of 25 percent spares.
d.Discrete inputs and outputs (DI and DO) shall have two terminals per point with
adjacent terminal assignments. All active and spare PLC and controller points shall
be wired to terminal blocks.
e.Analog inputs and outputs (AI and AO) shall have three terminals per shielded
pair connection with adjacent terminal assignments for each point. The third
terminal is for shielded ground connection for cable pairs. Ground the shielded
signal cable at the PLC cabinet. All active and spare PLC and controller points shall
be wired to terminal blocks.
f.Wire and tube markers shall be the sleeve type with heat impressed letters and
numbers.
g.Only one side of a terminal block row shall be used for internal wiring. The field
wiring side of the terminal shall not be within 6 inches of the side panel or
adjacent terminal, within 8 inches of the bottom of freestanding panels, within 3
inches of stanchion mounted panels, or within 3 inches of adjacent wireway.
h.Circuit power from the SCADA cabinet out to field devices (switches, dry contacts,
etc.) that are used as DI to the PLC input cards shall be isolated with an isolating
switch terminal block with flip cover that is supplied with a dummy fuse. One
isolating switch terminal block per loop numbered piece of equipment and one
per spare I/O point is acceptable.
i.All PLC DI to the field shall be isolated with an isolating fuse switch terminal block
with a flip cover and a neon blown fuse indicator.
5.All wiring to hand switches and other devices which are live circuits independent of
the panel’s normal circuit breaker protection shall be clearly identified as such.
6.All wiring shall be clearly tagged and color coded. All tag numbers and color coding
shall correspond to the panel wiring diagrams and loop drawings prepared by the PCSI.
All power wiring, control wiring, grounding, and DC wiring shall utilize different color
insulation for each wiring system used. The color coding scheme shall be:
24VDC + Blue
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24VDC- Brown
120VAC (H or L1) Yellow
120VAC (N or L2) White
120 VAC hot wiring derived from a UPS Yellow with Black stripe
system
Ground Green
Digital Input Purple
Digital Output Red
Analog Input White (Loop) Black (Signal)
Analog Output Grey
HART White (Loop) Orange (Signal)
Digital Input (120VAC) Pink
Three-phase power Brown, Orange, Yellow, and Green
ground, or as specified in Division
26 for Electrical
7.Provide surge protectors on all incoming power supply lines at each panel per the
requirements of Division 40, Section 40 61 00, Process Control System – General
Provisions.
8.Each field instrument furnished under Division 40 and shown on the Drawings as
deriving input power from the control panel(s) shall have a separate power
distribution circuit with a circuit breaker or fuse and blown fuse indication. All
instruments requiring 120VAC power shall be powered from the UPS source in the
panel where the instrument signals lands.
9.Provide 24VDC redundant power supplies to power field instruments and panel
devices. 24VDC power supplies shall be as specified in this Section.
10.Use of adhesive backed cable tie mounts is not acceptable. Cable ties shall be
permanently fixed to the panel structure, as needed for controlling cable routing
within the panel.
11.Wiring trough for supporting internal wiring shall be plastic type with snap-on covers.
The side walls shall be open top type to permit wire changing without disconnecting.
Trough shall be supported to the subpanel by stainless steel screws. Trough shall not
be bonded to the panel with glue or adhesives.
12.Each panel shall be equipped with switched light fixture(s) as specified in this Section.
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13.Each panel shall have a specification grade duplex convenience receptacle with ground
fault interrupter, mounted internally within a stamped steel device box with
appropriate cover. Convenience receptacle shall not be powered from a UPS and shall
be protected by a dedicated fuse or circuit breaker.
14.Each panel shall be provided with an isolated copper grounding bus for all signal and
shield ground connections. Shield grounding shall be in accordance with the
instrumentation manufacturer's recommendations.
15.Each panel shall be provided with a separate copper power grounding bus (safety) in
accordance with the requirements of the National Electrical Code.
16.Each panel shall have control, signal, and communication line surge suppression in
accordance with Division 40, Section 40 61 00, Process Control System – General
Provisions.
17.All microprocessor-based electronic devices in the panel that are powered by 120VAC
shall be powered by the UPS.
18.Each panel shall be provided with a circuit breaker to interrupt incoming power.
Provide a minimum of two spare 20-amp breakers.
19.Additional electrical components including transformers, motor starters, switches,
circuit breakers, etc., shall be in compliance with the requirements of Division 26.
B.Pneumatic Tubing:
1.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
2.Pneumatic tubing shall be a minimum of 1/4-inch O.D. 316 stainless steel with
compression fittings. All tubing shall be rigidly supported and run in horizontal or
vertical planes.
3.All pneumatic equipment shall be provided with separate shut-off valves. Flexible
polyethylene tubing shall be used on all devices mounted on hinged doors, etc.
4.A screened vent shall be provided on all enclosures using pneumatic instruments.
5.All pneumatic tubing shall be routed in separate bundles or wireways, and shall be
separated from all electrical wiring by a minimum of 3 inches.
C.Relays not provided under Division 26 and required for properly completing the control
function specified in Division 40, Division 26, or shown on the Drawings shall be provided
under this Section.
D.The orientation of all devices including PLC and I/O when installed shall be per the
manufacturer’s recommendations. No vertical orientation of PLC racks shall be allowed
unless specifically indicated by the manufacturer as an acceptable mounting alternative
and also approved by the Engineer.
E.Purge system for enclosures located in hazardous areas.
4.07GROUNDING
A.Provide grounding straps between each enclosure door and the enclosure.
B.Provide equipment grounding conductor terminals.
C.Provide equipment ground bus with lugs for connection of all equipment grounding wires.
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D.Multi-section panels shall be bonded together with an equipment grounding conductor or
an equivalent grounding bus.
E.Identify equipment grounding conductor terminals with the word “GROUND,” the letters
“GND” or the letter “G,” or the color green.
F.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.
G.Ensure the continuity of the equipment grounding system by effective connections through
conductors or structural members.
H.Design so that removing a device does not interrupt the continuity of the equipment
grounding circuit.
I.Provide an equipment-grounding terminal for each incoming power circuit, near the phase
conductor terminal.
J.Size ground wires in accordance with NEC and UL Standards, unless noted otherwise.
K.Connect all exposed, non-current-carrying conductive parts, devices, and equipment to the
equipment grounding circuit.
L.Connect the door stud on the enclosures to an equipment-grounding terminal within the
enclosure using an equipment-bonding jumper.
M.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.
4.08ACCESSORIES
A.Corrosion Control:
1.Panels shall be protected from internal corrosion by the use of corrosion-inhibiting
vapor capsules VC by Zerust, AHCI by Hoffman, or equal.
B.Emergency Alarm Beacons:
1.LED type beacon alarm lights shall be rated for the location and area classification in
which it will be installed. Provide NEMA 4X for non-hazardous installations and NEMA
7 for hazardous areas. Lens color shall be red unless specified otherwise on the
Drawings or Specifications.
2.Beacons shall be by Federal Signal, Edwards, or Equal.
C.Emergency Alarm Horns:
1.Alarm horns shall be electromechanical type rated for at least 80dB at 10 feet. Provide
NEMA 4X for non-hazardous installations and NEMA 7 for hazardous areas.
2.Alarm horns shall be 350 or 31X series by Federal Signal, 878EX by Edwards, or Equal.
D.Folding Shelf:
1.The shelf shall be suitable for a laptop computer and shall be placed such that an open
laptop computer does not interfere with any door-mounted devices. It shall not
interfere with any internal panel components when the door is closed and shall
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automatically lock in the horizontal position when raised. The folding shelf shall be
approximately 18 inches wide by 12 inches deep and shall have a minimum distributed
load rating of 100 pounds. All parts shall be made of heavy gauge steel and shall be
painted white or finished to match the interior panel color.
E.Light Fixtures:
1.Each panel shall have a single tube, LED light fixture with a minimum of 450 lumens
light output rating, mounted permanently to the interior ceiling of the enclosure. Light
fixtures shall be 120VAC switched and shall be complete with the lamp.
2.Multiple door enclosures shall have a light fixture and switch at each door and wired in
parallel to a single circuit.
F.Nameplates:
1.All panels and panel devices shall be supplied with suitable nameplates which identify
the panel and individual devices as required. Unless otherwise indicated, each device
nameplate shall include up to three lines, with the first line containing the device tag
number as shown on the drawings, the second line containing a functional description
(e.g., Raw Water Pump No. 1), and the third line containing a functional control
description (e.g., Start).
2.Unless escutcheon plates are specified or unless otherwise noted on the Drawings,
nameplates shall be 3/32-inch thick, black and white, Lamicoid with engraved
inscriptions. The letters shall be white against a black background unless otherwise
noted. Edges of the nameplates shall be beveled and smooth. Nameplates with
chipped or rough edges will not be acceptable.
3.Nameplate fasteners and mounting shall be epoxy adhesive or stainless steel screws
for cabinet-mounted nameplates.
4.For every panel, provide a panel nameplate with a minimum of 1-inch-high letters.
Provide legend plates or 1-inch by 3-inch engraved nameplates with 1/4-inch lettering
for identification of door-mounted control devices, pilot lights, and meters.
5.Single lamicoid nameplates with multiple legends shall be used for grouping of devices
such as selector switches and pilot lights that relate to one function.
G.Print Storage Pockets:
1.Print storage pockets shall be provided on the inside of each panel. The storage
pockets shall be steel, welded on to the door, and finished to match the interior panel
color. The storage pocket shall be sufficient to hold all of the prints required to service
the equipment. The print pocket shall contain an 11 x 17 control schematic and an 11 x
17 wiring diagram or diagrams. The wiring diagram shall contain all wire numbers,
device names and terminal numbers. Drawings shall be laminated in clear plastic for
preservation of the drawings.
H.Receptacles:
1.Provide specification grade, industrial duplex receptacles with ground fault interrupter
within a stamped steel device box/cover. UPS powered receptacles shall be clearly
labelled and color coded to distinguish them from general powered receptacles.
I.Sun Shields:
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1.Sun shields shall be fabricated from minimum 12 gauge aluminum. Units shall be
designed, fabricated, installed, and supported to fully cover and shade the top, sides,
and back of the enclosure; and to partially shade the front panel of the enclosure from
direct exposure to sunlight from sunrise to sunset.
2.Depending on overall size, sun shields may be fabricated in single or multiple segments
for attachment to the enclosure support framing or to separate freestanding framing
around the enclosure.
3.Sun shields shall not be attached directly to the enclosure by drilling holes through or
welding studs to, the enclosure surfaces; and shall be designed and mounted to
provide a minimum 3-inch air gap all around the enclosure for air circulation and heat
dissipation.
4.The top section of all sun shields shall be sloped at a minimum angle of 5 degrees from
horizontal. For wall-mounted enclosures, the top section shall slope downward away
from the wall and towards the front of the enclosure. For freestanding, floor-mounted
and frame mounted-enclosures, the top section shall slope downward towards the
back side of the enclosure.
5.The front edge of the top section of all sun shields shall incorporate a narrow and
more steeply sloped drip shield segment which sheds water away from the front of the
enclosure and prevents it from dripping or running directly onto the front panel of the
enclosure.
6.All seam welds used in sun shield fabrication shall be continuous and shall be ground
smooth.
7.All exposed corners, edges, and projections shall be smooth rounded or chamfered to
prevent injury.
J.Terminal Blocks:
K.Terminal blocks shall be DIN rail mounted, compression type, fused, unfused, or switched
as shown on the Drawings or specified elsewhere in Division 40. Terminal blocks shall be
rated for at least 15 amps at 600 volts, and have terminals suitably sized for the AWG of
connecting wires. Terminal blocks shall be Allen-Bradley 1492-JDG3FB, with associated
accessories (Cross-Connectors: 1492-SJ8A-4, End Anchors: 1492-GM35). Terminal blocks
shall be combined on steel DIN rail to form terminal strips. DIN rail shall be mounted on
3.75” (minimum) stand-off to elevate it above the enclosure back panel. Each terminal strip
shall have hinged marking surfaces which snap on. Typewritten labels shall denote terminal
strip numbers and shall match numbers shown on shop drawings, O&M manuals and wiring
diagrams. Marking surfaces shall be Allen-Bradley 1492-GMC.
L.Isolating switch terminal blocks shall have a flip cover that is supplied with a dummy fuse
and neon blown fuse indicator. Isolating switch terminal blocks shall be Model 1492-H7 as
manufactured by Allen Bradley, or Equal.
M.Multi-level terminal blocks, Spring-type terminal blocks or strips are not acceptable.
N.Provide a minimum of 25 percent spare terminal blocks.
O.Wireway:
1.Provide flame-retardant plastic wiring duct, slotted with dust cover, by Panduit or
Equal.
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4.09ELECTRICAL COMPONENTS
A.General:
1.Refer to Division 26 Electrical.
2.The control panel shall be provided with a main power circuit breaker and individual
fuses for each 120VAC and 24VDC logical circuit.
3.All operating control devices and instruments shall be securely mounted on the
exterior door. All controls shall be clearly labeled to indicate function and shall be in
accordance with the electrical area classification indicated on the Drawings.
4.The control panel shall be provided with a lightning and surge protection unit on the
line side of the main circuit breaker. Unit shall be 600 Volt, three-phase, General
Electric “Tranquell” Series, or equal.
B.24 VDC Power Supplies:
A.General 1.Provide a 24 VDC power supply in the control panel
to power field instruments, panel devices, etc., as
required. Equip the power supply with a power
on/off circuit breaker.
2.Size the 24 VDC power supply to accommodate the
design load plus a minimum 25 percent spare
capacity.
3.Mount the 24 VDC power supply such that dissipated
heat does not adversely affect other panel
components.
B.Function 1.Input Power: 115VAC, plus or minus 10 percent at
60 Hz.
2.Output Voltage: 24VDC.
3.Line Regulation: 0.05 percent for 10 volt line change.
4.Load Regulation: 0.15 percent from 0-100 percent
loading.
5.Ripple: 3mV RMS.
6.Operating Temperature: 0 to 50 degrees C.
7.Indication: LED status display.
8.Alarm Outputs: Relay contacts for status of on/off
and alarm.
C.
Physical 1.Din-Rail mounting.
D.Options/ 1.Provide output overvoltage and overcurrent
Accessoriesprotective devices with the power supply to protect
instruments from damage due to power supply
failure and to protect the power supply from
damage due to external failure.
2.Redundant power supply units and switching diodes
shall be provided if specifically noted on the
Drawings or Specifications.
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E.Manufacturer 1.Allen Bradley 1606 Series.
2.IDEC.
3.Phoenix Contact – Quint Series.
4.PULS Dimension Q Series.
5.TDK-Lambda DLP Series.
6.Equal.
C.Digital Panel Meter:
A.General 1.Electronic, 3.5-digit, 0.56-inch-high efficiency LED
display.
2.Display shall accept 4-20 mA DC input signal and provide
indication in Engineering Units of measured variable.
3.Display rating shall be compliant with the hazardous area
classification in which the unit is installed.
B.Function 4.Power: 115VAC or 24VDC.
5.Input: 4-20mA DC into 100 Ohms.
6.Indication: Minimum of 0.56-inch high LED display.
7.Performance: Linear input accuracy plus or minus 0.05
percent of calibrated span, plus or minus 1 count.
8.Operating Temperature: 0 to 50 degrees C.
9.Alarm Outputs: Relay contacts for status of on/off and
alarm.
C.Physical 1.Case size nominal 2.5-inch-high by 5-inch-wide by 6-inch
deep.
2.Case type: Watertight and dust-tight (NEMA 4X).
3.Mounting: Flush panel suitable for high density mounting
arrangements.
D.Options/ 1. None.
Accessories
E.Manufacturer 1.Omron.
2.Precision Digital.
3.Red Lion.
4.Equal.
D.Intrinsic Safe Relays, Switch Amplifiers and Solenoid Drivers:
A.
General 1.Solid state electronic type used to isolate and
transfer digital signals from a hazardous area to a
safe area. Intrinsic Safety is used to protect and
allow safe operation of electrical equipment within
hazardous areas by limiting the energy available for
ignition.
2.Intrinsic safety device rating shall be compliant with
the hazardous area classification in which the
protected field device is installed.
B.Function 1.Relays shall match power supply provided.
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2.Relays shall be located in non-hazardous areas.
3.Operating Temperature: 0 to 50 degrees C
(minimum).
4.Input: One or two channels.
5.Output: One or two output channels.
6.Power: Loop or externally powered per application
requirements.
C.Physical 1.Din-Rail mounting.
D.Options/ 1.Provide all needed power supplies and accessories
Accessoriesfor proper barrier operation.
E.Manufacturer 1.Allen Bradley 937 Series.
2.PepperL+Fuchs WE-System or K-System.
3.Weidmuller ACT20x Series.
4.Equal.
E.Intrinsic Safety Barriers (Analog and Temperature Signals)
A.General 1.Intrinsic safety barriers shall be passive devices
requiring no external voltage supply and supplied
with series resistors, series fuse and shunt zener
diodes to limit the transfer of energy to levels
required by intrinsically safe protection between safe
and hazardous locations.
2.Intrinsic safety device rating shall be compliant with
the hazardous area classification in which the
protected field device is installed.
B.
Function 1.Barriers shall be located in non-hazardous areas.
2.Operating Temperature: 0 to 50 degrees C
(minimum).
3.Input: One or two channels.
4.Output: One or two output channels.
5.Power: Loop or externally powered per application
requirements.
C.Physical 1.Din-Rail mounting.
D.Options/ 1.Provide all needed power supplies and accessories
Accessoriesfor proper barrier operation.
E.Manufacturer 1.Allen Bradley 937 Series.
2.PepperL+Fuchs WE-System or K-System.
3.Weidmuller ACT20x Series.
4.Equal.
F.Pilot Type Indicating Lights:
A.General 1.Energy efficient Solid State LED Lamps.
2.Unit rating shall be compliant with the hazardous area
classification in which the unit will be installed.
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B.Function 1.Units shall be provided with low voltage LED lamps
suitable for the voltage supplied.
2.Lamps shall be replaceable from the front of the unit.
C.Physical 1.Lights supplied with 120, 240, or 480 VAC power shall
have integral reduced voltage transformers.
2.Lens caps shall be approximately 30mm diameter with a
minimum rating of NEMA 4X.
3.Lens cap color:
a) Running, on, open – Red.
b) Stopped, off, closed – Green
c) Alarm – Amber.
d) White - Power on.
e) Blue - All other status indications not covered by the
above.
D.Options/ 1.Provide legend faceplates engraved to indicate the
Accessoriesrequired function of each device.
2.Provide Push-to-Test lamp test option.
E.Manufacturer 1.Allen Bradley 800 Series.
2.Eaton.
3.General Electric.
4.Schneider Electric.
5.Crouse Hinds (NEMA 7).
6.Equal.
G.Potentiometers:
A.General 1.Potentiometers shall be heavy-duty oil tight type sized
at least 30mm in diameter.
2.Potentiometer rating shall be compliant with the
hazardous area classification in which the unit will be
installed.
B.Function 1.At least 270-degree dial turn range.
C.Physical 1.Suitable for panel mounting.
2.Potentiometers shall have knob or wing lever
operators.
3.Minimum of 300 VAC/VDC voltage rating.
4.Minimum resistive element rating of 1,000 Ohms.
5.Potentiometers shall be approximately 30mm
diameter with a minimum rating of NEMA 4X.
D.Options/ 1.Provide legend plate denoting potentiometer
Accessoriesfunction.
E.Manufacturer 1.Allen Bradley 800 Series.
2.Eaton.
3.General Electric.
4.Schneider Electric.
5.Equal.
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H.Selector Switches and Pushbuttons:
A.General 1.Control devices shall be heavy-duty oil tight type with
stackable contact blocks.
2.Control device rating shall be compliant with the
hazardous area classification in which the unit will be
installed.
B.Function 1.Provide contact arrangement and switching action as
required for the control system specified.
C.Physical 1.For 120 VAC service, provide contacts rated 10 amps
at 120 VAC; for 24 VDC service, provide silver sliding
contacts rated 5 amps at 125 VDC; for electronic
(millivolt/milliamp) switching, provide contacts rated
lamp at 28 VDC.
2.Selector switches shall have knob or wing lever
operators.
3.Pushbuttons shall have flush type operators with
color as listed below, unless noted as otherwise:
1) Start or Open – Red.
2) Stop or Close – Green.
3) Alarm Reset – Black.
4.Control devices shall be approximately 30mm
diameter with a minimum rating of NEMA 4X.
D.Options/ 1.Provide legend plates denoting switch/pushbutton
Accessoriesposition/function.
2.Provide guard rings for all E-Stop, mushroom type
pushbuttons.
E.Manufacturer 1.Allen Bradley.
2.Eaton.
3.General Electric.
4.Schneider Electric.
5.Crouse Hinds (NEMA 7).
6.Equal.
I.General Purpose Relays and Time Delays:
A.General 1.General purpose plug-in type, magnetic control relays.
Provide surge protection across the coil of 120VAC relays
and free-wheeling diodes across the coil of 24VDC relays.
2.New PLC and RIO cabinet discrete I/O rating shall be
24VDC. Provide interposing relays for all discrete input
and output signals that enter the PLC/RIO cabinet with
120VAC rating.
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3.Provide additional relays when the number or type of
contacts shown exceeds the contact capacity of the
specified relays, or when higher contact rating is required
to interface with starter circuits or other equipment.
4.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.
B.Function 1.Contact arrangement/function shall be as required to
meet the specified control function. Mechanical life
expectancy shall be in excess of 10 million.
2.Duty cycle shall be rated for continuous operation. Units
shall be provided with integral indicating light to indicate
if relay is energized.
3.Solid state time delays shall be provided with polarity
protection (DC units) and transient protection.
4.Time delay units shall be adjustable and available in
ranges from 0.1 second to 4.5 hours, as required for the
application.
C.Physical 1.For 120 VAC service, provide contacts rated 10 amps at
120 VAC; for 24 VDC service, provide contacts rated 5
amps at 28 VDC; for electronic (milliamp/millivolt)
switching applicator, provide gold-plated contacts rated
for electronic service.
2.Relays shall support DIN rail mounting and be equipped
with dust- and moisture-resistant covers.
D.Options/ 1.Provide mounting sockets with pressure type terminal
Accessoriesblocks rated 300 volt and 10 amps.
2.Provide mounting rails/holders as required.
E.Manufacturer 1.Allen Bradley.
2.IDEC.
3.Potter & Brumfield.
4.Square D.
5.Equal.
J.Signal Relay Switches (Current Limit Alarms)
A.General 1.Solid state, ASIC technology, electronic type.
B.Function 1.Input: 4-20mA.
2.Output: Isolated contact output, double pole double
throw, rated 5 amps at 120VAC.
3.Accuracy: 0.1 percent.
4.Protection: RFI.
5.Deadband: Adjustable between 0.1 and 5.0 percent of
span.
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6.
Setpoint Adjustment: Single Point alarms shall be
adjustable to trip on rising or falling input signal; dual
point alarms shall be adjustable to trip on rising and
falling input signals.
7.Repeatability: Trip point repeatability shall be at least
0.1 percent of span.
C.Physical 1.Din-Rail mounting.
D.Options/ 1.Provide Single-Trip, DPDT or Dual-Trip, SPDT outputs as
Accessoriesrequired by application.
E.Manufacturer 1.Schneider Electric/Eurotherm ActionPak or Ultra
Slimpak.
2.Acromag.
3.PepperL+Fuchs.
4.Equal.
K.Signal Isolators/Boosters/Converters:
A.General 1.Solid state, ASIC technology, electronic type.
B.Function 1.Input: Current, voltage, frequency, temperature, or
resistance as required.
2.Output: Current or voltage as required.
3.Accuracy: 0.15 percent.
4.Protection: RFI.
5.Isolation: Complete isolation between input channels,
output channels and power supply.
6.Adjustments: Zero and span.
C.Physical 1.Din-Rail mounting.
D.Options/ 1.Provide Single-Trip, DPDT or Dual-Trip, SPDT outputs as
Accessoriesrequired by application.
E.Manufacturer 1.Schneider Electric/Eurotherm ActionPak or Ultra Slimpak.
2.Acromag.
3.Equal.
L.Signal Selectors, Computation, and Conditioning Relays
A.General 1.Solid state, ASIC technology, electronic type.
B.Function 1.Inputs: 4-20mA.
2.Outputs: 4-20mA.
3.
Accuracy: 0.35 percent of span.
4.Protection: RFI.
5.Isolation: Complete isolation between input channels,
output channels and power supply.
6.Adjustments: Multi-turn potentiometer for zero, span,
scaling, and biasing.
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7.Operation: The relay shall multiply, add, subtract, select,
extract the square root, or perform the specified
conditioning/computation function required. All inputs
shall be able to be individually rescaled and biased as
required.
C.Physical 1.Din-Rail mounting.
D.Options/ 1.Provide Single-Trip, DPDT or Dual-Trip, SPDT outputs as
Accessoriesrequired by application.
E.Manufacturer 1.Schneider Electric/Eurotherm ActionPak or Ultra Slimpak.
2.Acromag.
3.Equal.
M.Panel Intrusion Door Activate Switch
A.General 1.Internal door switch with electrical contact output
activated when door is opened and deactivated when
closed.
B.Function 1.One normally closed 120/250 VAC Rated switch with
pushbutton rod activator and mounting plate.
C.Physical 1.Suitable for door mounting within control panel.
2.14 gauge steel mounting plate.
D.Options/ 1.Provide all necessary mounting hardware and wiring.
Accessories
E.Manufacturer 1.Hoffman.
2.Equal.
5.00EXECUTION
5.01GENERAL
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
FOE!PG!TFDUJPO!
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40 68 00 APPLICATIONS ENGINEERING SERVICES
1.00 GENERAL
1.01 SCOPE OF WORK
A.The PCSI/ASP shall furnish all Production Control System (PCS) programming work required
to achieve a fully integrated and operational system as specified herein and in other Division
40 Specification Sections.
B.PCSI/ASP is responsible to obtain and provide any and all information required from other
Divisions, as listed in the related work below, to complete the work under this Section.
C.Provide all PLC process controller programming, plant Human Machine Interface (HMI)
programming, Operator Interface Terminal (OIT) programming, and iFiX system
configuration including database(s), control logic programs, graphics, communications links,
and historical archiving as specified herein for:
1.Configuring new PLC modules, providing PLC program, PCS HMI graphics modifications,
and Control pop-up screens to comply with the Owner existing HMI graphic screens; and
include all PCS monitoring and controls associated with the modifications within this
project.
2.The system shall utilize Rockwell Automation PlantPAx as the standard set of graphic
symbols library.
D.Auxiliary and accessory programming structures necessary for proper system operation and
performance shall be included whether or not they are shown on the Drawings.
1.All equipment shall be controlled in full conformity with the existing PLC programs,
process control descriptions, specifications, engineering data, and instructions.
2.All work shall be coordinated with plant operating personnel to minimize impacts on
daily operation. Delays caused by any reason shall be noted and formally submitted to
the OWNER/ENGINEER in the form of a letter.
3.To facilitate the OWNER's future operation and maintenance, all applications
programming shall follow OWNER’s pre-established programming conventions.
PCSI/ASP shall conduct a workshop with OWNER/ENGINEER to gain an understanding of
OWNER’s conventions and use this as the basis for developing the HMI and PLC
applications.
4.Existing HMI and OIT display screens shall be modified to incorporate work defined in
the Contract Documents.
E.The PCSI/ASP is responsible for the following:
1.HMI, PLC and OIT system configuration, testing, startup, and training.
2.Provide for and test communications and functionality between all connected devices
such as PLCs, and the HMI software packages as depicted on the system architecture
drawings.
3.All Applications Software Development and Programming shall be performed in
accordance with the OWNER’s pre-established programming conventions.
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4.The PCSI/ASP shall coordinate and schedule all testing procedures with the General
CONTRACTOR, OWNER’s Representative, and OWNER.
5.The PCSI/ASP shall coordinate and schedule all testing procedures for the PLC and
SCADA HMI of existing facilities with the OWNER.
6.Provide all process controller programming and HMI configuration including
development/modification of control programs, tag database configuration, graphic
screens, communication links, and historical archiving, as specified herein. The process
control system specified herein shall perform the following generalized functions:
a.Provide PLC and HMI tags for new and existing equipment including PCS identifier,
equipment identifier, and loop numbers as shown in the Drawings.
b.Perform real-time process control, including proportional integral derivative control
action, sequencing, process calculations, etc.
c.Collect and store accurate, reliable operating information for present and future
uses.
d.Accumulate and store equipment running times for use in preventative
maintenance.
e.Provide color graphic displays and reports for use by the system operating and
supervisory personnel.
f.Provide trending for all analog values.
g.Provide control system diagnostics.
h.All process control functions including PID, calculations, sequencing, timing, etc.,
shall be done in the process controller. The HMI software shall perform the real-
time database, report generation, graphic screens, program development, setpoint
modification, data archiving, etc.
i.The system shall allow the operator to manually control (by keyboard entry and
mouse type pointing device) the status of pumps, valves, etc. (i.e., on off, open
close, setpoint value, etc.), when viewing the appropriate graphic screen on the
HMI.
7.Operator Interface:
a.Quantity of graphic displays to be provided or modified shall be as required to
depict all monitoring and control requirements defined herein and in the Contract
Documents. All processes and equipment shown on the P&ID drawings shall be
shown in a similar manner and as specified herein. The graphic displays shall
represent all process flow paths and all associated equipment units, pumps, meters,
valves, gates, feed systems, and auxiliary systems. As a minimum, the following
graphic displays and types shall be provided as new or modified versions of existing:
1).Process Detail Displays
2).Alarm Summary Display.
3).Control Strategy Setup Displays.
4).Equipment Control Pop-up Displays for each instrument, pump, valve, PLC, and
other equipment.
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5).Trend Displays for each instrument reading including tank level, system
pressure, flow and analyzer etc.
6).Navigation screens.
7).Reports.
1.02 RELATED DOCUMENTS
A.Refer to Section 40 61 00, Process Control and Instrumentation Systems - General
Provisions, for additional submittal, meeting, coordination and functional requirements.
B.Refer to Section 40 61 21, Process Control System – Testing, for testing requirements of the
ASP/PCSI.
C.Refer to Section 40 61 26, Process Control System – Training, for training requirements of
the ASP/PCSI.
D.Refer to Section 40 61 96, Process Control Descriptions, for programming requirements of
the ASP (Application Service Provider).
E.Refer to Section 40 66 00, Network Equipment, for requirements of network equipment to
be provided by the PCSI.
F.Refer to Section 40 67 00, Control Panels and Components, for control panels, network
panels and components to be provided by the PCSI.
1.03 DEFINITIONS
A.ASP – Application Services Provider.
B.PCSI – Process Control System Integrator.
C.HMI – Human Machine Interface (Plant HMI, HVAC, PMCS, OIT).
D.I/O – Input/Output.
E.IP – Internet Protocol.
F.MAC – Media Access Control.
G.OIT – Operator Interface Terminal.
H.PCS – Production Control System.
I.PID – Proportional, Integral, Derivative.
J.P&ID – Piping and Instrumentation Diagram.
K.PLC – Programmable Logic Controller.
L.RTU – Remote Telemetry Unit.
M.SCADA – Supervisory Control and Data Acquisition.
N.VLAN – Virtual Local Area Network.
1.04 SUBMITTAL REQUIREMENTS
A.General
1.Refer to Division 01 for general submittal requirements.
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2.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
B.Submittal List: Separate submittals shall be supplied as listed below.
Specification
Item Submittal Title Submittal Number Number
1. I/O List Submittal 40 68 00-01 40 68 00
2. Process Graphics and Detailed Control Narratives 40 68 00-02 40 68 00
3. Controller Program 40 68 00-03 40 68 00
4. Historical Data 40 68 00-04 40 68 00
5. Software Maintenance Documentation 40 68 00-05 40 68 00
** Refer to indicated Specification Section or associated paragraph in this Section for details of submittal
requirements and quantities.
C.I/O List Submittal
1.Provide documentation of the I/O list, including ranges, alarm setpoints, and historical
data collection information.
a.SITE NAME: Identifies the site name where the data point is part of.
b.PLC TYPE: The identifier of the type of PLC.
c.IO MODULE NAME: The identifier of the name of module.
d.IO MODULE VOLTAGE: Module voltage rating.
e.IO MODULE RACK/SLOT/CHANNEL: The identifier of rack/slot/channel for each
point.
f.IO MODULE ADDRESS: The identifier of module address.
g.IO TYPE: Analog In (AI), Analog Output (AO), Discrete Input (DI), or Discrete Output
(DO).
h.TAG NUMBER: The identifier assigned to a device or variable that performs a
function in the control system. Tag numbering shall follow SAWS Tag Naming
Standards.
i.DESCRIPTION: A description of the function of the device or variable (text that
includes signal source, control function, etc.).
j.ENGINEERING RANGE/STATE: The range in engineering units corresponding to an
analog 4-20 mA signal or scalable variable (LO/HI), or the text description
corresponding to each state of a discrete point (ON/OFF).
k.ENGINEERING UNITS (EU): The engineering units associated with the Analog I/O or
scalable variable.
l.ALARM/EVENT: Designation of the data point as an Alarm or an Event.
m.ALARM PRIORITY: Priority level of the alarm (if applicable).
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n.ALARM LIMITS: Include alarm limits based on the existing HMI database settings.
These values will be verified by the system programmer during startup and
commissioning.
o.HI HI: Assignment of the High-High alarm limit and priority (if applicable).
p.HI: Assignment of the High alarm limit and priority (if applicable).
q.LO: Assignment of the Low alarm limit and priority (if applicable).
r.LO LO: Assignment of the Low - Low alarm limit and priority (if applicable).
s.HISTORICAL INFO: Designation of the point to be placed into the historian. The
actual points to be placed into the Historian will be finalized in coordination with the
OWNER.
t.UPDATE RATE: Rate at which a historically collected data point is to be collected by
the historian.
u.HISTORICAL LOGGING: Designation if the data point is to be historically collected.
2.Allow for up to a two-week review cycle of the I/O List Submittal.
D.Detailed Control Narratives Submittal
1.This submittal shall cover all of the application programs developed to implement the
control functions specified herein and in the Contract Documents.
2.The process control schemes shall be developed based on information from the
specifications and drawings. This submittal shall include the following, as a minimum:
a.A brief scope of the control function.
b.List of all scanned inputs to the control function.
c.A short narrative of the control strategy.
d.Any assumptions made in developing the program.
e.I/O database list showing all inputs and outputs (i.e., AI, DI, AO, DO), calculated
points and pseudo points associated with the control function.
f.PLC communication and hardware monitoring.
g.List of all operator inputs/outputs to and from the control function. A description of
the operation of any panels shall be described as it relates to the control function.
h.List of all Add-On Instructions and faceplates utilized for developing the control
program.
3.All anticipated failure contingencies shall be described in detail.
4.All applications programs shall be developed in a structured manner and shall follow an
intuitive arrangement. Programs shall utilize standard program templates or
subroutines for repetitive logic such as equipment control, flow total calculations, and
equipment runtime calculations. All applications programs shall be submitted in 8.5-inch
x 11-inch format. All programs shall be fully annotated throughout to facilitate diagnosis
by instrumentation technicians with basic programming knowledge.
5.This submittal shall also include copies of the PLC I/O configuration tables and I/O
reference usage table. In addition, any special switch settings or hardware configuration
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requirements, such as communications port configurations, shall be described in detail
and submitted.
E.Process Graphics Submittal:
1.Submit all proposed graphic displays (for the HMI and OITs), trends, alarms, and logs to
support the control strategy narratives.
2.Submitted graphic displays and trends shall be no less than 8.5 inch x 11 inch full-color
prints.
3.Quantity of graphic displays to be provided shall be as required to depict all monitoring
and control requirements defined herein and in the Contract Documents. All processes
and equipment shown on the drawings shall be shown in a similar manner. The graphic
displays shall represent all process flow paths and all associated equipment units,
pumps, meters, valves, gates, feed systems, and auxiliary systems, whether monitored
or not.
4.Pre-defined trend displays shall be developed for easy recall using index display or
standard display recall buttons. Pre-defined trends shall be developed for all analog
inputs. Grouping of analog inputs shall be as defined by the OWNER/ENGINEER. A
maximum of eight points shall be assigned to a trend.
5.For graphics that will be duplicated several times for similar equipment or purposes,
submit for only the first equipment as a typical display.
6.Each HMI process operation function, such as operation button and alarm acknowledge
functions, shall be configured with the proper operation security privileges to prevent
unauthorized operation. Each HMI process operation function such operation button
and alarm acknowledge functions shall be configured with operation security to prevent
unauthorized operation.
7.Allow for up to a two-week review cycle of the Process Graphics Submittal.
F.Controller Program Submittal:
1.Submit software logic programs and documentation for function block language used
for the application engineering effort.
2.Program documentation shall include all function blocks, individual rungs, network,
and/or command descriptions with abundant comments to clearly identify function and
intent of each code segment. Link between “coil” and “contact” shall be clearly
presented, the function of each timer described, the purpose of each subroutine call
labeled and defined, etc. Program documentation shall be sufficiently clear to allow
determination of compliance with the process control requirements included in the
Process Control Descriptions.
3.The submittal shall demonstrate that all logic provided under this project follows the
same structure and format and reflects a common programming approach. Any custom
subroutines or function blocks shall be described in detail and shall include all inputs
with allowable ranges, the outputs, and the internal logic of the block.
4.Submit details of control system communication. Submit hardware and software
configuration information in sufficient detail to verify performance of the
communication system as detailed herein and on the Drawings. Include description of
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drivers and impact of drivers on controller memory configuration. Any specific
communication block memory addresses shall be defined.
5.Submit a memory usage report for the controller. This report shall indicate both used
and unused memory addresses. Include constant and variable memory assignment
records that tabulate area, location, number, and description of each numeric constant
or variable stored in memory.
6.Method and logic for special housekeeping programs and routines including
redundancy, clock synchronization, value scaling, alarm handling, archiving, etc. Submit
information for all digital systems including controllers and HMI equipment.
7.Submit cross reference index of I/O allocation, controller memory address, HMI graphic
systems address, and HMI graphic screen where the I/O point will appear. Every physical
I/O point, as well as calculated or virtual I/O required for the implementation of the
process scheme, shall be included.
8.Make additional changes to the software configuration, beyond those identified in the
initial draft submittal, based on comments during the factory and field tests and during
the commissioning process as required.
9.Allow for up to a two-week review cycle of the Controller Program Submittal.
G.ASP Testing Plan Submittal:
1.ASP Testing Plan shall be incorporated into the Testing Plan Submittal required within
Section 40 61 00.
a.Refer to Section 40 61 21 – Process Control System Testing.
2.This submittal will outline the approach to testing the various components of the system
to validate that the HMI and PLC programming meets the requirements. In addition,
sample test forms and procedures will be included to allow the OWNER/ENGINEER an
opportunity to comment on format and content prior to the PCSI developing the
detailed test procedures. Additional components of this submittal shall include test
approval and punch list procedures.
3.Test Procedure: Submit the procedures proposed to be followed for each test.
Procedures shall include test descriptions, forms, and checklists to be used to control
and document the required tests. Include sign-off forms for each testing phase or loop
with sign-off areas for the PCSI and OWNER/ENGINEER. Refer to PART 3 for specific
testing requirements, and submit separate procedures for each specified test phase.
H.ASP Training Plan Submittal:
1.ASP Training Plan shall be incorporated into the Training Plan Submittal required within
Section 40 61 00.
a.Refer to Section 40 61 26 - Process Control System Training.
2.This submittal shall provide an overview of the proposed ASP training for the OWNER’S
operations and maintenance staff. The training program shall be coordinated with the
OWNER’S staff so that the schedule and content meets their needs. The approved
submittal shall be used as the basis for development of training manuals that will be
provided to all attendees.
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3.Submit outlines of the specific training, resumes of trainers, pre-requisite requirements
for each class, and general samples of handouts for review. The training plan shall also
include:
a.Definitions of each course.
b.Specific course attendance.
c.Schedule of training courses including dates, duration, and locations of each class.
d.Complete copy of all proposed handouts and training materials. Training
information shall be logically arranged in a three-ring binder with all materials
reduced to a maximum size of 11 inch x 17 inch, then folded to 8.5 inch x 11 inch for
inclusion into the binder.
4.Refer to PART 3 for specific training requirements.
I.Historical Data
1.PCSI/ASP shall provide a Historical Data submittal including the following:
a.List of existing equipment tags to be modified by this Contract shall be submitted.
b.List of all new signals to be historically collected and stored, including sampling rate
and duration for which data will be immediately accessible through the system.
J.Software O&M Manual Submittal
1.At the conclusion of the commissioning activities but prior to final acceptance of the
system, operations and maintenance manuals covering all operations and maintenance
procedures for the applications software and system configuration shall be furnished.
2.All software applications, programs, and configuration files shall be provided on
electronic media disks independent of computer hard disk files. Files shall be provided
on machine-loadable media capable of being used by a technician to restore the
installed software using the existing hardware and software programs.
3.The manuals shall contain operating and maintenance data written specifically for this
project. The manual shall include bookmarks.
4.At a minimum, the following information shall be provided in the manuals:
a.A comprehensive index.
b.All documentation from previous submittals updated to reflect the as-built system.
c.Detailed service, maintenance, and operation instructions for each item supplied,
including procedures for backing up files and archiving historical data.
d.List of personnel to be contacted for warranty and emergency services, including
name, address, telephone number, pager or cell phone number, fax number, and
email address.
e.Printouts of every graphic display with all dynamic points referenced.
f.Printouts of all configuration files.
g.Printouts of all documented PLC programs.
h.Electronic media disks containing all HMI, PLC, OIT and other custom-configured
files used on the Project.
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i.Final PID Loop Tuning Parameters for all associated control loops.
1.05 REFERENCE STANDARDS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.06 COORDINATION MEETINGS
A.Preliminary HMI and PLC Conventions Workshop
1.The PCSI/ASP shall conduct an HMI and PLC Conventions workshop with
OWNER/ENGINEER to gain an understanding of OWNER’s existing conventions for HMI
and PLC applications development. The focus of the workshop will be to gain consensus
on how the HMI and PLC applications will be developed for this project. To aid in these
discussions, PCSI/ASP shall prepare for the workshop by first requesting sample HMI and
PLC applications from the OWNER that represent the conventions desired for this
project. Upon receipt, PCSI/ASP shall review and use as the basis for developing a
minimum of three (3) process graphic screens proposed for this project that mimic the
current conventions. PCSI/ASP shall demonstrate the use of these three process
graphics during the workshop to OWNER/ENGINEER to gain concurrence that a
thorough understanding of the OWNER’s existing conventions has been gained.
2.In addition to the three process graphics, PCSI/ASP shall also review the OWNER’s PLC
programs to gain an understanding of the methodologies currently being used. PCSI/ASP
shall be prepared to review their understanding of these during the workshop with
particular emphasis on how the OWNER performs common program organization,
control schemes, calculations, data mapping, tag naming, etc. so that consensus can be
gained on how these features will be implemented for this project.
3.For both HMI and PLC applications, PCSI/ASP shall make recommendations for
improvement during the workshop for OWNER/ENGINEER to consider.
4.Attendees at the workshop shall include representatives from the PCSI, ASP, BLOWER
ASP, OWNER, and ENGINEER.
5.Subsequent to the workshop, PCSI/ASP shall document their understanding of the
decisions made during the workshop in the form of meeting minutes and submit to
OWNER/ENGINEER for concurrence and approval. Once approved, these meeting
minutes will serve as the basis for how all HMI and PLC applications shall be developed
for the project.
B.Control Narrative:
1.The PCSI/ASP shall submit an itemized list of information required to create a draft
submittal of HMI display screens and PLC Control Narrative prior to this meeting. This
request should also include any Supporting Documents required (Owner provides
integrator with latest HMI configuration files, existing PLC program if needed, I/O list
template, etc.).
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2.Owner/Engineer meets with the PCSI to discuss control strategy and answer questions
pertaining to control narratives and also discuss basic display layout and answer questions
pertaining to graphic displays. The PCSI shall produce a basic set of displays showing
overall layouts and display hierarchy. These displays consist primarily of major pieces of
equipment and how they will be arranged. This allows the Owner/Engineer an opportunity
to confirm the information can be displayed as requested and to make adjustments.
3.Owner/Engineer will also review the project schedule milestones and deliverables with the
PCSI/ASP.
4.This meeting will last up to two hours.
C.Final Graphics Display and Historical Data Workshop
1.After submittal of the Preliminary Graphic Displays, Owner/Engineer meets with the
PCSI/ASP to discuss final display layouts and answer questions pertaining to graphic
displays. The PCSI/ASP shall display graphics and lead discussions to finalize displays and
demonstrate conformance to Owner HMI standards. This meeting shall allow
Owner/Engineer an opportunity to confirm the information can be displayed as requested
and to make adjustments.
2.PCSI/ASP shall discuss with Owner and Engineer the historical data and reports required
for this Project.
a.Refer to Division 40, Section 40 61 00A, Blower ASP Proposal and Scope.
1.07 DELIVERY, STORAGE, AND HANDLING
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions, for project/site requirements.
1.08 NOMENCLATURE AND IDENTIFICATION
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
1.09 PROJECT/SITE REQUIREMENTS
A.Refer to Division 40, Section 40 61 00, Process Control and Instrumentation Systems –
General Provisions.
2.00 PRODUCTS (NOT USED)
3.00 EXECUTION
3.01 GENERAL
A.The PCSI/ASP shall support the CONTRACTOR and suppliers to aid in the installation
requirements of the Process Control System defined in Division 40.
B.The PCSI/ASP shall coordinate the overall implementation of the control system
components defined within the Contract Documents.
C.The PCSI/ASP shall be familiar with the existing HMI configuration and configuration
standards before start of HMI configuration.
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D.All HMI configurations including main screens, pop-up screens, screen displays, equipment
global objects, screen navigation, alarm and event configurations, security, database, screen
scripts, I/O drivers, and historian shall conform to the existing HMI configuration without
any exception.
E.The PCSI/ASP shall be familiar with the existing PLC configuration and configuration
standards before start of PLC configuration.
F.The PCSI/ASP is responsible for providing all applications programming and configuration
services to accomplish the control and monitoring functions as described herein and in the
Contract Documents.
3.02 DISPLAY LAYOUT
A.The PCSI/ASP shall not change the HMI display layout or screen Navigation Toolbar.
B.All displays shall contain and continuously update the displayed process variables, date, and
time of day. All process values shall be displayed in engineering units. All displays shall
incorporate references to both instrumentation tag numbers and plant equipment numbers.
C.The system shall allow the operator to control equipment such as pumps and valves as
defined in the control loop drawings and control loop descriptions. All control actions
require a two-step action.
D.Unless specifically noted, all timers, setpoints, alarm actuation levels, etc., shall be
adjustable from the operator interface.
E.Hierarchical Structure
1.CONTRACTOR shall not change graphic display hierarchical structure.
2.Color Convention and Animation
a.Color conventions and animation are referred to HMI Display and Equipment Global
Objects that include analog valve displays, digital point status displays, setpoint
entry, equipment animations, equipment color, equipment popup screen, alarm and
event display, and trend screens.
3.PCSI/ASP shall use standard HMI displays and equipment global objects for instruments
and equipment.
4.All developed HMI displays and equipment shall be in compliance with existing HMI
color conventions and animations.
F.Security
1.All HMI process operational functions, such as an operation button or alarm
acknowledgement, shall be configured with user-level security to prevent unauthorized
operation. PCSI/ASP shall configure the security areas and functions to points and
displays.
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4.00 EXISTING HMI AND OIT GRAPHIC SCREENS
4.01 GENERAL
A.Refer to the specification attachment (40 68 00A - Applications Engineering Services –
Attachment A – Existing HMI Screens) for the existing HMI screens at the operator
workstations that shall be modified under this project per the contract documents.
B.Refer to the specification attachment (40 68 00A - Applications Engineering Services –
Attachment A – Existing HMI Screens) for the existing operator interface terminal screens
and pop-up screens for the different project areas.
C.Provide any and all HMI software programming and configurations required to create new
HMI screens and modify the existing HMI screens as needed per the contract documents. All
the descriptions on the HMI/OIT screens shall match the contract documents including the
Piping and Instrumentation (P&ID) diagrams and the Input/Output list.
D.New and modified HMI and OIT graphic screens shall be consistent with the existing HMI
graphic screens methodology and appearance.
END OF SECTION
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40 68 00A APPLICATIONS ENGINEERING SERVICES – ATTACHMENT A – EXISTING HMI
SCREENS
1.00GENERAL:
A.See HMI Screens Below for examples of configured HMI screens and pop-ups for the
different project areas to be modified or recreated under this project as per the contract
documents. Provide any and all HMI software programming and configuration required to
create new Operator HMI screens and modify the existing Operator HMI screens as needed
per the contract documents. All the descriptions on the HMI/OIT screens shall match the
contract documents including the Piping and Instrumentation (P&ID) diagrams and the
Input/Output list. The existing HMI Screens at the central location are available upon
request by the Contractor.
B.This attachment is for reference only to show the existing HMI screens at the operator
workstations and the operator interface terminals. The existing screens need to be modified
or recreated within this project based on the P&IDs and the control descriptions. Other
existing HMI screens for these project areas may not be shown.
C.The following project areas are covered in this attachment:
1.OIT Screens – Resaca Lift Station
2.OIT Screens – HMI-1 (PCM-1 Control Room ECR-1 Building)
3.OIT Screens – Blower Master CONTROL Panel
4.OIT Screens – Blower Panel 1 (Typical for all the 4 blower OITs)
5.HMI Screens – Main (at the operator workstations)
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2.00OIT SCREENS – RESACA LIFT STATION:
A.General
1.New HMI/OIT screens shall be created for the Resaca Lift Station per the contract
documents. See the existing OIT screens below for the minimum HMI screen
requirements. An Overview screen shall be created to show all the pumps and
instruments as per the P&ID and the other contract documents.
B.Resaca Lift Station East-West Selector Switch
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C.Resaca Lift Station Pump Rotation Selection
D.Resaca Lift Station Lead-Lag Setpoints
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E.Resaca Lift Station Level Setpoints
F.Lag Function Lead-Lag Speed Setpoints
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G.Resaca Lift Station Pump Failure Alarm Screens
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3.00OIT SCREENS – HMI-1 (PCM-1 CONTROL ROOM ECR-1 BUILDING)
A.General
1.Modify the HMI/OIT screens and popups as needed to reflect the new changes under
this project per the contract documents. See the existing OIT screens below.
B.Overview Screen
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C.Blower 1
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D.Blower 2
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E.Blower 3
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F.Blower 4
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G.Air Header
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H.Aeration Basin 1
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I.Aeration Basin 2
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J.Aeration Basin 3
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K.Aeration Basin 4
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L.Air Supply Odor
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M.Power Status
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4.00OIT SCREENS – BLOWER MASTER CONTROL PANEL
A.General
1.New HMI/OIT screens shall be created for the Blower Master Control Panel per the
contract documents. See the existing OIT screens below for the minimum OIT screen
requirements. Modify the existing HMI screens and popups as needed to reflect the new
changes under this project.
B.Main Menu
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C.System Scaling – Pg.1
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D.System Scaling – Pg.3
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E.Lead/Lag Status
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F.Lag Start/Stop Setpoints
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G.System Control
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H.Blower Status
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I.DO Mode Overview
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J.DO Alarm Setpoints
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K.Lead/Lag Setup
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L.MOV Control & PID Setup
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M.Basin #1 Control & PID Setup
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N.Basin #2 Control & PID Setup
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O.Startup Sequence Setpoints
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P.Trend Menu
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Q.Basin DO Trend
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R.Basin Flow Trend
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S.PSI Trend
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T.Alarm Management
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5.00OIT SCREENS – BLOWER PANEL 1 (TYPICAL FOR ALL THE 4 BLOWER OITS)
A.General
1.New HMI/OIT screens shall be created for each of the four Blower local Control Panel
per the contract documents. See the existing OIT screens below for the minimum OIT
screen requirements. Modify the existing HMI screens and popups as needed to reflect
the new changes under this project.
B.Main Menu
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C.SCFM Calculation Parameters
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D.HOA Control
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E.Valve Control
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F.Startup Setpoints
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G.Flow PID Control
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H.Flow PID Tuning Parameters
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I.Scaling Setpoints
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J.Status Screen – Page 1
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K.Status Screen 2
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L.Status Screen 3
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M.Alarm Management
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N.Setpoint Menu
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6.00HMI SCREENS – MAIN
A.General
1.Modify the HMI screens and popups as needed to reflect the new changes under this
project per the contract documents. See the existing HMI screens below.
B.Overview Screen
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C.Headworks
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D.Aeration Basins
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E.One Line Diagram
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F.UV Channels
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G.Sludge Blowers
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H.Aeration Basin Blower
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I.Wet Well Surge Pumps
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J.Trending
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K.Communications & PCM Status
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40 70 00 PROCESS CONTROL SYSTEM - INSTRUMENTS
1.00GENERAL
1.01SCOPE OF WORK
A.This Section includes instrumentation used in process control system. Refer to Attachment
A of this Section for the Instrumentation Schedule.
B.The PCSI shall furnish any and all labor, materials, equipment and related services
necessary to install all equipment required for a complete and operational instrumentation
and controls system as shown on the Drawings and specified herein.
1.02RELATED WORK
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.03SUBMITTAL REQUIREMENTS
A.Refer to Division 01 for general submittal requirements.
B.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions for
spare parts, submittal, and other additional requirements. PSCI shall submit any deviations
of submitted instruments from the requirements of this specification within a line-by-line
table of compliance. The deviations will be reviewed by the Owner/Engineer for
consideration of approval.
C.Operation and Maintenance Data: Provide literature detailing all custom configured
parameters and back-up/restore procedures for each network component.
1.04REFERENCE STANDARDS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
1.05QUALITY ASSURANCE
A.General: Equipment shall be the Manufacturer’s latest and proven design. Specifications
and drawings call attention to certain features, but do not purport to cover all details
entering into the design of the instrumentation system. The completed system shall be
compatible with the functions required and the equipment furnished by the Contractor.
B.Power Supplies: The drawings and specifications indicate the energy sources that will be
provided. Any other devices or power supplies necessary to obtain proper operation of the
instrument system from these energy sources shall be furnished with the instrumentation.
1.06DELIVERY, STORAGE, AND HANDLING
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
B.Deliver instrumentation in packaging designed to prevent damage from static electricity
and physical damage.
C.Store instrumentation according to manufacturer requirements. At a minimum, store
indoors in clean, dry space with uniform temperature to prevent condensation. Protect
instrumentation from exposure to dirt, fumes, water, corrosive substances, and physical
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damage. Also, protect from all forms of electrical and magnetic energy that could
reasonably cause damage.
1.07APPROVALS/CERTIFICATIONS
A.Instruments intended for installation within hazardous locations shall have Factory Mutual
(FM), Canadian Standards Association (CSA), and CENELEC approvals and certifications at or
beyond the hazardous area classification in which they are to be installed.
1.08DEVIATIONS
A.No deviations from the specification requirements will be allowed, except those listed in
the table of compliance that are reviewed and approved by the Owner/Engineer.
2.00PRODUCTS
2.01GENERAL
A.All cabling, mounting hardware, and accessories required to install all components of the
instrumentation system shall be provided by the PCSI and/or Contractor.
B.Instrumentation shall be suitable for installation at the location as shown on the Drawings.
C.When multiple instruments of a particular type are specified, and each requires different
features, the required features are described on the Drawings or the Instrument Device
Schedule.
D.Instruments shall be provided with HART communication as specified. HART
communication is used for set-up and maintenance for all instruments/transmitters.
E.For all analog signals from devices located outdoors, surge protection shall be provided as
specified in section40 61 00, Process Control and Instrumentation Systems – General
Provisions.
2.02SPARE PARTS
A.Refer to Division 40, Section 40 61 00, Process Control System – General Provisions.
2.03WARRANTY
A.Provide a minimum of one-year manufacturer warranty for all supplied instrumentation
and equipment.
2.04FLOW METER - ELECTROMAGNETIC TYPE – FLANGED
A. General 1. Microprocessor-based Pulsed DC electromagnetic induction type providing
a signal which is linear to the flow rate of a conductive liquid in a full pipe.
Use of insert flow meters or multiple single point probes inserted into a
spool piece is unacceptable.
2. Measure flow of liquids with a minimum conductivity of 5 microS/cm and
for demineralized water with a minimum conductivity of 20 microS/cm.
B. Function 1. Input Power: 120 VAC to flow transmitter.
2. Accuracy: +/- 0.5 percent of rate for velocities of 1 to 30 fps.
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3. Turndown: 10:1 minimum, at flow rates above 1 fps.
4. Process Temperature: Up to 60 degrees C, unless otherwise noted.
5. Ambient Temperature: -10 to 50 degrees C.
6. Provide RFI Protection and zero stability feature.
7. Operating Temperature: 23 to 176 degrees F.
8. Outputs: One Isolated 4-20 mA HART linear analog output as indicated in
the instrument schedule; and one pulse signals for totalizing, alarm, or
serial communication output, unless otherwise noted.
9. Display: LCD, two-line Digital indicator scalable to flow rate engineering
units or 0-100 percent.
Stability: Combined temperature effects shall be less than 0.2 percent of
10.
maximum span per 50 degrees F temperature change. Effect on accuracy,
due to static pressure changes, shall be negligible.
11.Drift: 0.10 percent per six months for 4-20 mA output.
12. Meter shall be capable of running empty indefinitely without damage to
any component.
C. Physical 1. Meter Tube: Stainless steel, NEMA 6P rated for indefinite submergence in
20 feet of water for inside of the vault and Carbon steel with 304 Stainless
steel interior and NEMA 4X rated for other applications. All exterior
surfaces shall be painted with chemical and corrosion-resistant epoxy
finish.
2. Flanges: ANSI B 16.5 Class 150 or AWWA Class D epoxy-coated carbon steel
flanges as required to match the associated piping system.
3. Wetted Parts: 316 SS, bullet nosed or elliptical self-cleaning type
electrodes.
4. Liner: Hard Rubber or Polyurethane, in conformance with Manufacturer’s
recommendations for the intended service.
5. Transmitter: NEMA Type 4X, unless installed in locations such as vaults that
will experience submergence. In those applications NEMA 6P is required.
Where hazardous areas are indicated on the Drawings, the equipment shall
be rated for that area.
6. Hazardous Area Rating: Class 1 Div 2.
7. Transmitter Mounting: Integral to meter tube, or suitable for remote
mount on pipe or stand mounting indoors or outdoors as indicated on the
Drawings and Instrument Schedule.
8. The transmitter display shall be oriented on the upright position to be
easily readable.
9. For outdoor installations, the terminal box conduit entries shall not be on
the top.
D. Options/ 1. Provide all cables, connectors, mounting hardware, and tubing required for
Accessories a fully operational instrument system. Signal cable between the flow tube
and transmitter to be provided by the system manufacturer with sufficient
length of cable for continuous installation between the flow tube and the
transmitter.
2. Provide 50 feet cable length for the transmitter remote installation.
3. Provide keypad or remote device where required for transmitter
configuration depending on area classification.
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4. Factory calibration: All meters shall be factory calibrated. A copy of the
report shall be included in the O&M manual.
5. Grounding: Meter shall be grounded in both sides. Provide two ground
rings, ground wires, gaskets, etc., as required. All materials shall be suitable
for the liquid being measured.
6.Provide data, signal, and power surge protection for each instrument.
7. Provide a handheld programmer for each transmitter where full setup is
not available for the instrument directly.
8. Sunshade with necessary stainless steel mounting hardware, fitting, and
conduits for protecting transmitter display for all the outdoor installations;
preventing display from temperature changes caused by solar radiation;
and providing partial protection from falling objects, rain, snow, and
windblown sand. (See detail drawings.) Sunshield shall be equipped with
glare shield with continuous hinge spot welded to sunshield to protect the
transmitter display.
E. Manufacturer 1. Endress + Hauser, 400 series.
2. Rosemount, 8732 series
3. Khrone, Optiflux 2000 or 4000 series.
4. Approved Equal.
2.05LEVEL SWITCH – FLOAT TYPE – SUSPENDED OR FIXED MOUNT
A. General 1. Direct acting mercury-free float with enclosed switch and integral cable.
Ball or cylindrical type selected based on application.
2. For water and wastewater service, unless otherwise noted.
B. Function 1. Activation: up to 8-inch differential.
2. Switch Rating: 150 VDC/VAC and 1 Amp, 25 W maximum.
3. Switch Type: Totally encapsulated, form-C (NO/NC), non-inductive
contact.
C. Physical 1. Float: 316 stainless steel Teflon-coated, PVC or ABS. Up to 5-1/2 inch
diameter.
2. Heavy-duty, PVC-jacketed integral to float.
3. Mounting: Suitable for internal weight, pipe, or cable mounting.
D. Options/ 1. Provide all cables, connectors, SS mounting hardware, and tubing
Accessories required for a fully operational instrument system.
2. Cable length shall be sufficient so that no splice or junction box is
required in the vault or hazardous area.
3. Provide cast-aluminum weatherproof junction box outside vault or
hazardous area, with terminals for all floats and tapped for conduit
connections.
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E. Manufacturer 1. Siemens Water Technologies, Model 9G-EF.
2. Contegra FS-90.
3. Magnetrol, model T-10.
4. Gems, Series M.
5. Approved Equal.
2.06LEVEL TRANSMITTER – RADAR
A. General 1. Non-contacting continues wave or pulsed radar to measure level of a
liquid or a solid material.
2. Single electronic unit connected directly to an antenna with integral level
display panel.
B. Function 1. For thru-air applications, the antenna system shall be either a 316 stainless
steel horn or a PVDF encapsulated sensor with a drip-off design or flush-
mounted PEEK type, supporting distances up to 31 feet.
2. Level measurement shall be unaffected by high humidity and/or high
condensation between the antenna and the process fluid.
3. Level measurement shall be capable of accuracy of 0.10 inches or better.
4. An adjustment for empty and full vessel shall be done using either HART or
Bluetooth.
C. Physical 1. Transmitter Mounting as indicated in instrument schedule and detail
drawings
2. Transmitter shall be 24 VDC loop powered and support HART
communication on top of a standard 4-20 mA signal.
3. Transmitter shall be microprocessor based and shall include a remote
digital display capable of showing level in feet and inches when required.
D. Options/ 1. Remote display capable of showing level in feet and inches. Remote digital
Accessories display readout shall be Endress Hauser RIA46, or RIA452. Field panel
should be provided for the outdoor installations.
E. Manufacturer 1. Endress+Hauser, Micropilot FMR 20 Series and RIA.
2.07PRESSURE TRANSMITTER – GAUGE AND ABSOLUTE TYPE
Microprocessor-based, intelligent type to measure pressure.
A. General 1.
Range: As indicated in Section 40 70 00, Field Instrument, Attachment A.
B. Function 1.
Transmitter range shall be standard and as close as possible such that the pressure
range to be measured is set at 80 percent of the manufacturer’s standard range.
Over range protection: Capable of withstanding over-pressure up to 1.5 times the
2.
maximum pressure range without damage.
Accuracy: +/- 0.1 percent of calibrated span for 15:1 rangeability. (includes effects
3.
of linearity, repeatability and hysteresis)
Stability: ±0.2% of upper range limit for 12 months.
4.
Ambient Operating Temperature: -4 to 176 degrees F.
5.
Temperature Effect: Combined effects shall be less than 0.2 percent of maximum
6.
span per 82.4 degrees F temperature change.
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Static Pressure Effect: Effect on accuracy due to static pressure changes shall be
7.
negligible.
Output: 4-20 mA DC with HART protocol.
8.
Power: 24 VDC loop powered.
9.
Damping: Adjustable between 0 and 60 seconds.
10.
Adjustable zero and span.
11.
Housing: NEMA 4X (IP66), epoxy-coated aluminum.
C. Physical 1.
Wetted Metallic Parts: 316 stainless steel and Teflon coated if available.
2.
Wetted Seals: Teflon.
3.
Sensor Fill Fluid:
4.
Utilize halocarbon fill for process applications involving strong oxidizing agents.
Agents include but are not limited to: Cl2, HFS, FeCl, Na0H, and Na0Cl.
Utilize manufacturer's standard fill for other applications.
Ensure fill is suitable for application temperatures
Display: LCD displaying Pressure in engineering units, 3 1/2 digits.
5.
Process Connection: 0.5-inch FNPT.
6.
Provide 316 stainless steel instrument tubing and fittings, isolation valve(s), and
Options/
D. 1.
Accessories
mounting bracket as required.
Provide a 316 stainless steel or Hastelloy C valve manifold with Normal, Zero,
2.
Blocked, Calibrate, and Blowdown functions suitable for application.
Mounting: Remote or direct as indicated in Section 40 70 00, Field Instrument,
3.
Attachment A.
Endress+Hauser PMP71B.
E. Manufacturer 1.
Rosemount 3051S.
2.
Approved Equal.
3.
2.08DIFFERENTIAL PRESSURE TRANSMITTER
A. General 1. Microprocessor-based, intelligent type to measure differential pressure.
B. Function 1. Range: As indicated in Section 40 70 00A, Field Instruments, Attachment A.
2. Output: 4-20 mA DC with HART protocol.
3. Stability: ±0.2% of upper range limit for 12 months.
4. Accuracy (includes effects of linearity, repeatability and hysteresis): ± 0.1% of
calibrated span for 15:1 rangeability.
5. Ambient Operating Temperature: 4 to 176 degrees F.
6. Power: 24 VDC loop powered.
C. Physical 1. Housing: cast aluminum.
2. Transmitter Enclosure: NEMA 4X.
3. Wetted Metallic Parts: 316 stainless steel.
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4. Sensor Fill Fluid:
1)Utilize halocarbon fill for process applications involving strong
oxidizing agents.
a)Agents include but are not limited to: Cl2, HFS, FeCl, Na0H, and
Na0Cl.
2)Utilize manufacturer's standard fill for other applications.
a)Ensure fill is suitable for application temperatures
5. Display: LCD displaying Pressure in engineering units, 3 1/2 digits.
D. Options/ 1. Provide one set of spare gaskets.
Accessories
2. Install where specified or shown on Drawings.
3. Provide a 316 stainless steel or Hastelloy C five-valve manifold suitable for
application.
E. Manufacturer 1. Endress & Hauser.
2. Foxboro.
3. Rosemount.
4. Approved Equal.
2.09DIAPHRAGM SEAL - THREADED
A. General 1. Diaphragm Seal with flushing connection to isolates instrument from process fluids
which are corrosive or contain solids.
Rating: Equal to or greater than pipe rating.
2.
Diaphragm seal/tubing/instrument assembly shall be assembled, filled, calibrated,
3.
tested, and certified in a NIST traceable ISO 9001 certified calibration facility prior to
shipping to project site.
B. Function 1. Type: Thread attached, Welded Metal Diaphragm.
2. Exposed Surfaces: 316 stainless steel.
3. Filling Screw: Include on all units.
4. Pressure Limit: 1,000 PSI.
5. Upper housing with bleed screw, Lower housing with flushing connection.
Tubing as required to connect with associated instrument; 1/4-inch inner diameter
6.
minimum flexible stainless steel.
7. Accuracy: +/- 0.5 percent of span or better (ASME B40.100 Grade 2A).
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C. Physical 1. Process connection: Minimum 1/4- inch NPT.
2. Upper housing: Carbon steel, cadmium plated.
Lower housing: 316 stainless steel, Hastelloy C (for chlorine application) Ensure
3.
material is suitable for application.
4.
Diaphragm: 316 stainless steel, Tantalum (for chlorine application) Ensure material
5.
is suitable for application.
6.
Exposed surfaces: 316 stainless steel.
7.
Sensing Sleeve: Buna-N.
Bolts, nuts, and plugs: 18-8 stainless steel or 316 stainless steel.
8. Provide Type 316 stainless steel armored capillary for all remote installations.
Options/
D. 1. Provide one set of spare gaskets.
Accessories
2. Installed where specified or shown on Drawings.
E. Manufacturer 1. Ashcroft.
2. Emerson Rosemount.
3. Approved Equal.
2.10MANIFOLD
A. General 1. Provide fully machined surfaces.
B. Function 1. Type: Two-valve, three-valve, or five-valve manifold as shown on the drawings or as
indicated in the specifications.
C. Physical 1. Manifold shall be of 316 stainless steel and Hastelloy C for chlorine applications.
2. Flanged or trans-mount as shown on the drawings or as indicated on the
specifications.
D. Options/ 1. Provide one set of spare gaskets.
Accessories
2. Install where specified or shown on Drawings
E. Manufacturer 1. Ashcroft.
2. Emerson Rosemount.
3. Approved Equal.
2.11SIGNAL DUPLICATOR
A. General 1. Provide flow signal duplicators as per the drawings and as specified here in.
B. Function 1. Universally configurable 4-way signal duplicator with plug-in connection technology
for the electrical isolation and duplication of analog signals.
2. Input signal: 4-20mA
C. Physical 1. Provide a 316SS NEMA 4X Signal Duplicator Enclosure to house signal duplicators,
ethernet remote I/O, Protocol Convertor module, surge protection devices, and
power distribution module included for wiring 24VDC to Duplicator/Isolator
modules.
D. Options/ 1. Install where specified or shown on the drawings.
Accessories
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E. Manufacturer 1. Phoenix Contact MINI MCR-2-UNI-UI-2UI.
2. Approved Equal.
3.00EXECUTION
3.01GENERAL INSTALLATION
A.Install and connect the equipment in accordance with the manufacturer's instructions.
B.Each instrument shall be supplied with a 316 stainless-steel tag identifying the instrument
tag number as shown on the Drawings and specified herein.
3.02STARTUP AND TRAINING
A.As specified in Division 40, Section 40 61 26 Process Control System – Training.
B.If indicated in the instrumentation paragraphs above, the instrument manufacturer or
manufacturer’s certified service representative shall provide start-up and training services.
This work shall not be done by the PCSI or ASP contractor.
C.The start-up services shall be to calibrate, oversee the installations of the sensor, and start
up the sensor/transmitter in order to provide reliable measurement at the instrument and
to a remote system. The vendor shall work with the PCSI and ASP to verify the transmitter
sends correct information to the remote system (i.e., that the scaling and units are the
same at the instrument and on the remote operator interface).
FOE!PG!TFDUJPO!
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UIJT!QBHF!JOUFOUJPOBMMZ!MFGU!CMBOL!
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SECTION 40 70 00A
ATTACHMENT A - INSTRUMENT SCHEDULE
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Op/Op/51!81!11SbohfCz
04-I-01New Resaca RWW-LIT/LE N/AResaca LS East Wetwell LevelLevel Indicating Transmitter - 2.06Class I Div I, NEMA 6P Sensor (Full Submergence) With Remote 0'-30'PCSI
PLC4001RadarMounted NEMA 4X Digital Display Indicator. Field meter to be
installed inside a 316SS NEMA4X enclosure. 1" NPT On The Top
With LB conduit bodies And 1” Rigid Conduit. Provide Flood
Protection Tube. Provide intrinsically safe barrier and surge
protection device for the instrument. The exact level sensor
location to be as per the manufacturer recommendation.
04-I-01New Resaca RWW-LSL N/AResaca LS East Wetwell Low LevelLevel Switch Low - Float2.05Weighted Float Type, Class I Div I5'PCSI
PLC4001
04-I-01New Resaca RWW-LIT/LE N/AResaca LS West Wetwell LevelLevel Indicating Transmitter - 2.06Class I Div I, NEMA 6P Sensor (Full Submergence) With Remote 0'-30'PCSI
PLC4004RadarMounted NEMA 4X Digital Display Indicator. Field meter to be
installed inside a 316SS NEMA4X enclosure. 1" NPT On The Top
With LB conduit bodies And 1” Rigid Conduit. Provide Flood
Protection Tube. Provide intrinsically safe barrier and surge
protection device for the instrument. The exact level sensor
location to be as per the manufacturer recommendation.
04-I-01New Resaca RWW-LSL N/AResaca LS West Wetwell Low LevelLevel Switch Low - Float2.05Weighted Float Type, Class I Div I5'PCSI
PLC4004
04-I-02New VPLC-PIT-4100N/ABio-Trickling Filter Water Line PressurePressure Indicating 2.07Provide 316SS three-valve manifold and diaphragm seal.0-100 psi *Vendor
4000Transmitter
04-I-02New VPLC-FIT/FE-4100N/ABio-Trickling Filter Water Line FlowFlow Indicating Transmitter - 44 31 110-30 gpm *Vendor
4000Paddlewheel Type44 31 16
04-I-02New VPLC-LIT-4100N/ANutrient Tank LevelLevel Indicating Transmitter - 2.06, and Class I Div I, NEMA 6P Sensor (Full Submergence) With Remote 0-3' *Vendor
4000Radar44 31 11Mounted NEMA 4X Digital Display Indicator. Provide intrinsically
44 31 16safe barrier and surge protection device for the instrument.
Provide Flood Protection Tube.
04-I-02New VPLC-LSL-4200N/ABio-Trickling Filter Low LevelLevel Switch Low - Float2.05, and 3' *Vendor
400044 31 11
44 31 16
04-I-02New VPLC-PDIT-4200N/ABio-Trickling Filter Differential Pressure Differential Pressure 2.08, , and Provide 316SS five-valve manifold.0-10 in w.c. Vendor
4000Indicating Transmitter44 31 11*
44 31 16
04-I-02New VPLC-PDIT-4401N/ACarbon Scrubber Differential Pressure Differential Pressure 2.08, and Provide 316SS five-valve manifold.0-10 in w.c. Vendor
4000Indicating Transmitter44 31 11*
44 31 16
04-I-02New VPLC-PDIT-4402N/ACarbon Scrubber Differential Pressure Differential Pressure 2.08, and Provide 316SS five-valve manifold.0-10 in w.c. Vendor
4000Indicating Transmitter44 31 11*
44 31 16
Page 1 of 2
Field Instruments
40 70 00A
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SECTION 40 70 00A
ATTACHMENT A - INSTRUMENT SCHEDULE
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Op/Op/51!81!11SbohfCz
05-I-01Existing PLC 1FIT/FE-5100N/ASeptage Hauler Station Inlet FlowFlow Indicating Transmitter - 2.044 Inch, 120 VAC, Remote Transmitter, Class 1 Div 2, NEMA 4X 0-500 gpm *Vendor
Electromagnetic Type - Sensor, NEMA 4X Transmitter, 150 # Carbon Steel Flanges, 50 FT
FlangedCable Length For The Transmitter Remote Installation. Sunshield
shall be equipped with glare shield with continuous hinge spot
welded to sunshield to protect the transmitter display.
05-I-01Existing PLC 1LT/LE-5200N/ASeptage Hauler Station Screen Unit LevelLevel Transmitter - Radar2.06Class I Div I, NEMA 6P Sensor (Full Submergence) With Remote 0-5' *Vendor
Mounted NEMA 4X Digital Display Indicator. Provide intrinsically
safe barrier and surge protection device for the instrument.
Provide Flood Protection Tube.
* Values provided for vendor furnished equipment are subject to change depending on the Equipment Manufacturer selected. Contractor shall coordinate values with Equipment Manufacturer.
Page 2 of 2
Field Instruments
40 70 00A
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SECTION 40 73 99
PIPING SYSTEM, PRESSURE GAUGES AND THERMOMETERS
GENERAL
1.1SUMMARY
Section Includes:
Work includes the furnishing, installation, testing, and placing in service the pressure
gauges, thermometers, and related accessories, as shown on the Drawings and
specified herein.
Related Sections:
Division 0
Division 1
Section 43 11 19, “Foul Air Fans”.
Section 44 31 11, “Biological Tower Type Odor Control System”.
Section 44 31 16, “Carbon Adsorber Odor Control System”.
1.2REFERENCES(NOT USED)
1.3SUBMITTALS
Product Data: Provide product data sheets and catalog information for each type of
pressure gauge.
Provide manufacturer’s warranty for each product indicated.
1.4DELIVERY, STORAGE, AND HANDLING
Deliver, handle,and store all components to be installed under this section in accordance
with the preselected equipment supplier’swritten Pre-Installation Delivery, Storage, and
Handling Instructionsand the requirements of Section 016000 “Product Requirements.”
PRODUCTS
2.1MANUFACTURERS
Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the
following:
Ashcroft, Inc.
AMETEK® U.S.Gauge
Weksler, Division of Ashcroft, Inc.
Wika instrument Corporation
2.2PRESSURE GAUGES
Description: Provide gauges of manufacturer’s standard commercial product, new and shall
embody the design characteristics stated for the respective class, size, type and service
scheduled herein or on the Drawings.
Gauge Class Designations:
Class 1: Pressure indicating.
Class 2: Vacuum indications, designed for vacuum indications.
Class 3: Indicate pressure or vacuum.
Gauge Size and Style:
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3-1/2 inches and smaller shall be glycerin filled in stainless steel cases.
Larger than 3-1/2 inches shall be steel zinc coated and finished with black
enamel.
Unless otherwise indicated, minimum dial size shall be 4-1/2 inches.
Bourdon Tube and Socket Material: Type 316 stainless steel.
Connection: 1/2-inch.
Accuracy: ASME B40.1, Grade 2A, ±0.5% full scale.
No stop pin to mask false zero reading.
Range: Unless otherwise specified or indicated on Drawings, pressure gauges shall have a
pressure range of 0 to 60 psi or a range covering the pressure of the piping, whichever is
greater.
Maximum operating pressure should not exceed 75% of the full-scale range, with
normal operating range in the middle half of the full-scale range, between 25% and
75%.
Temperature: 150°F maximum.
Vibration: If present, provide glycerin filled gauge.
2.3PULSATION DAMPENER
Description:
Provide an adjustable snubber consisting of a ball check and an adjustable needle
valve or fine thread choke valve, constructed of Type 316 stainless steel, 1/2-inch
NPT size.
Provide on inlet to pressure gauges where fluctuations due to pulsations are present.
2.4DIAPHRAGM SEALS
Description:
Consists of a thin flexible diaphragm mounted between two flanges between the
pressure gauge and the medium being measured. It serves a separating member
stopping the medium from entering the gauge preventing clogging and corrosion.
Materials: Top and bottom housing Type 316 stainless steel; diaphragm material
compatible with the process fluid.
Installation: Provide diaphragm seals ahead of pressure gauges for measuring pressure of
chemicals, grit slurry, and fluids containing solids.
2.5BALL VALVE
Three-piece body, full port, vented ball, block-out proof stem, Type 316 stainless steel trim,
reinforced TFE seat and seal, threaded ends, lever operator, rated 1000-psi CWP. Conforms
to MSS SP-110.
Manufactures:
Contromatics.
Crane Valve Group
NIBCO
2.6THERMOMETERS
Thermometers: Process grade bimetal thermometers, all-angle swivel connection, Type 316
stainless steel case, in accordance with ASME B40.3 at locations shown on the Drawings.
Designed for direct or remote reading as shown on Drawings.
Accuracy: ±1% of scale.
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Bulb: Stainless steel.
Stem Length:
Less than 8-inches: 3-1/2 inch.
8-inches through 10-inches: 6-inch.
Larger than 10-inches: 9-inch.
Dial: 4-1/2 inches diameter; dual scales, temperature both in Fahrenheit and Celsius,
with black numbers on white dial.
Range, Low Pressure Air Service:
Thermowells. Provide at all thermometer locations, fitted with plug and chain, and
conforming to the requirements specified for thermometers. Install all thermowells vertical
or at a 45-degree vertical angle to permit filling withconducting liquid for tests.
Extensions: Where thermometers are installed in insulated lines, use extension-neck
separable sockets.
Remote: Furnish remote bulb thermometers where specified and shown on the Drawings.
Provide thermometers with corrosion-resistance movements set in cast aluminum cases with
black enamel finish.
Dial: 4-1/2 inches diameter; dual scales, temperature both in Fahrenheit and Celsius,
with black numbers on white dial, unless otherwise specified.
Cable: Stainless steel interlocked spiral armor over stainless steel capillary tubing.
Unless otherwise indicated, located cases 5-1/2 feet above finish floor.
EXECUTION
3.1INSTALLATION
Install instruments in accordance with the Drawings and the manufacturer's instructions.
Identification: Refer to P&ID Drawings for instrument identification and applicable Division
26for electrical and 40Sections for instrumentation.
END OF SECTION
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SECTION 43 11 19
FOUL AIR FANS
GENERAL
1.1SUMMARY
Coordinating Supplier:
The EQUIPMENT SUPPLIER of the Biological Tower-Type Odor Control System
(Section 44 31 11) and Carbon Adsorber (Section 44 31 16) shall be responsible for
providing all equipment listed in this specification section.
Section Includes:
The EQUIPMENT SUPPLIER shall furnish, provide installation guidance, startup, and
test two (2) foul air fans, as shown in the Drawings, and as specified herein for a
complete and operable system. Each foul air fan unit shall include all equipment
components, materials, accessories, wiring, control system (compatible with the Plant
Control System (PCS)), and incidentals as required for functional equipment,
excluding ducts or dampers.
To ensure system compatibility, a single supplier is responsible for providing a
complete odor control system, the successful operation of each item of equipment in
the package, and for the integrated system which also includes a Biological Tower-
Type OdorControl System (Section 44 31 11). The responsibility of the EQUIPMENT
SUPPLIER shall include the approval of installation, system optimization, and
warranties for the components and performance of the complete Odor Control
System.
1.2REFERENCES
Drawings and general provisions of the Contract, including Special Conditions and Division 1
Specification Sections, apply to this Section.
Reference Standards: This Section contains references to the following documents. They
are part of this Section as specified and modified. In case of conflict between the
requirements of this Section and those of the listed documents, the requirements ofthis
Section shall prevail. Comply with applicable provisions and recommendations of the
following, except where otherwise shown or specified.
ABMA, American Bearing Manufacturers Association.
AMCA 210-97/ASHRAE 51-1985, Laboratory Methods of Testing Fans for Rating.
AMCA 300, Reverberant Room Method for Sound Testing of Fans.
ASHRAE 51-1985 Laboratory Methods of Testing Fans for Rating.
ASTM C 582, Specification for Contact-Molded Reinforced Thermosetting Plastic
Laminates for Corrosion Resistant Equipment.
ASTM D 2563, Practice for Classifying Visual Defects in Glass reinforced Plastic
Laminate Parts.
ASTM D4167-97 (2002), Standard Specifications for fiber-Reinforced Plastic Fans and
Fans.
IEEE 112, Standard Test Procedure for Polyphase Induction Motors and Generators.
NEC, National Electric Code.
NEMA, MG1 -Motors and Generators.
NFPA, National Fire Protection Association.
SSPC, Steel Structures Painting Council.
Underwriter’s Laboratories, Inc.
AMCA 211-94, Certified Ratings Program –Air Performance.
ANSI/AMCA 204-96, Balance Quality and Vibration Levels for Fans.
PS 15-69 –Custom Contact-Molded Reinforced-Polyester Chemical-Resistance Process
Equipment.
PLUMMER ASSOCIATES, INC.43 11 19-PAGE 1OF 14BIDSET
0537-038-01FOUL AIR FANSJANUARY 2023
ANSI/ASME B16.1 –Cast Iron Pipe Flanges and Flanged Fittings.
Inspection and Testing Requirements: The visual inspection of the equipment shall comply
with ASTM D 2563, Visual Acceptance Level II.
Listing, labeling or marking, as conforming to the standards of AMCA, Underwriter's
Laboratories, Inc., American National Standards Institute, Inc., or other nationally
recognized testing organization approved by Code, on various pieces of equipment furnished
shall be prima facie evidence of conformity with the approved standards for safety to life
and property.
Related Sections:
Section 01 33 10, “Submittal Procedures”
Section 01 75 25, “Equipment Testing and Startup”
Section 09 91 00, “Painting and Protective Coatings”
Section 40 05 36.13, “Foul Air Fiberglass Ductwork”
Section 40 05 51, “Common Requirements for Process Valves”
Section 44 31 11, “Biological Tower-Type Odor Control System”
Section 44 31 16, “Carbon Absorber Odor Control System"
Section 40 73 99, “Piping System, Pressure Gauges and Thermometers”
Section 26 20 00.01, “NEMA Frame Induction Motors, 600 Volts and Below”
Section 40 05 93, “Common Motor Requirements For Process Equipment”
5
1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Action Submittals:
EQUIPMENT SUPPLIER shall submit for review to OWNER or OWNER’S representative,
sufficient literature, detailed specifications, and drawings to show dimensions,
fabricator or manufacturer, speed, model, size, type, horsepower, service factors,
efficiency, materials used, design features, internal construction, weights, and any
other information required by OWNER or OWNER’S representative for review of odor
control fans and all appurtenances. No odor control fan equipment shall be accepted,
and installation shall not be allowed until such review has been completed.
Additional requirements for information to be included with Shop Drawings are
specified below:
Submittal for the odor control fans shall include as a minimum the following:
EQUIPMENT SUPPLIERshall provide a copy of this Section and indicate
for each specification item in this Section that the requirement is
acknowledged. All deviations from the contract documents shall be clearly
identified in a separate list.
Manufacturer’s certified rating data.
Certified Shop Drawings providing all important materials and details of
construction, dimension, and anchor bolt locations. (w/ FINAL PRINTS
AFTER APPROVAL).
Descriptive literature, bulletins, and catalogs of the equipment.
The total weight of the equipment.
A complete bill of materials.
A list of the EQUIPMENT SUPPLIER’s recommended spare parts. Include
gaskets, packing, etc., on list.
Data on noise in accordance with AMCA #300.
Description of surface preparation and shop primer and shop finish coating
as specified in this Section.
Inlet and outlet connection bolt hole patterns.
Results of factory dynamic balance of fan and field check of dynamic
balance of fan.
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Specific design parameters for this project including flow rates and
pressure losses for normal conditions. Include AMCA certified fan curves
showing efficiency, cfm, outlet velocity, static pressure, brake motor
horsepower, and decibel level ratings.
Motors:
Complete submittal per Section 26 20 00.01 “NEMA Frame
Induction Motors, 600 Volts and Below.”
Letter of Certification the motor is compatible with a variable
frequency drives when specified as adjustable speed operation.
Wiring Diagrams: If applicable, for power, signal, and control wiring
diagrams, including terminals and numbers.
Auxiliary Instrumentation and Devices: Datasheets and mounting
locations/details for auxiliary instrumentation and devices furnished with
equipment. The informationshall include associated mounting brackets
and hardware.
Results of factory dynamic balance of fanand field check of dynamic
balance of fan.
Shop Test Results:
Submit results of routine factory motor tests.
Submit results of material tests.
Field Test Results: Submit a written report providing the results of the required field
tests per Paragraph 1.5.Kof this Section.
Manufacturer's Reports: Submit a written report of the results of each visit by a
manufacturer's service person, including purpose and time of visit, tasks performed
and results obtained.
Operation and Maintenance Manuals: Submit complete installation, operation and
maintenance manuals, test reports, maintenance data and schedules, description of
operation, and spare parts information.Complete Operation and Maintenance (O&M)
Manuals shall be provided per Section 01 33 00, “Submittal Procedures”,and Division
1 requirements and shall include complete O&M information for all components of the
system. O&M Manuals shall be submitted at least thirty (30) days prior to final
acceptance of the system. In addition to standard information, the O&M manuals
shall include:
a.Fan sizing calculations. These shall include calculations of pressure loss through
the proposed synthetic media, and losses through the system.
b.Complete point-to-point wiring diagrams. Complete component bill of material
with manufacturers catalog cut sheets marked to show components provided.
c.Submit copies of final PLC and OIT program versions in native format.
Lubricant Specification: Furnish a lubricant specification for the type and grade
necessary to meet the requirements of the equipment.
Partial or incomplete submittals shall not be reviewed. Any exceptions from this
specification shall be itemized in an exceptions table.
Information Submittals:
Field Representative Resume
Qualifications Statement
Previous Installations List
Pre-Installation, Special Shipping, Delivery, Storage and Protection, and Handling
Instructions
Manufacturer’s instructions for installation.
Recommended Equipment Lubricants
Samples
Certificates
Software
Manufacturer’s Certification of Compliance.
Manufacturer’s Certificate of Proper Installation.
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Location and contact information of nearest stocking distributor of spare parts.
Suggested spare parts list to maintain the equipment in service for a period of one
year. Include a list of special tools required for checking, testing, parts replacement,
and maintenance, with current pricing information.
Welding certificates.
Startup and test schedule.
Source quality-control reports.
Field quality-control reports.
Closeout Submittals
Paint
Lubricants
Spare Parts
Operation and Maintenance Data
Warranty Documentation
Record Data Documentation
Extra Stock Materials
Tools and Software
1.5QUALITY ASSURANCE
All equipment of each type specified in this section shall be supplied by a single EQUIPMENT
SUPPLIER who is fully experienced, reputable and qualified in the manufacture of the
equipment to be furnished. The equipment shall be designed, constructed, and installed in
accordance with the best practices and methods.
Field Representative: The EQUIPMENT SUPPLIER shall furnish a qualified field representative
for the time indicated in Paragraph 3.5.A of this Section.Field representatives shall be
factory-employed personnel and have a minimum of two (2) years of experience with the
operation of and training on this type of equipment. Sales representatives will only be
considered acceptable service technicians if they have three (3) years of experience with the
operation of and training on this type of equipment from the EQUIPMENT SUPPLIER being
supplied and have started up 15 units of a similar size and type from the EQUIPMENT
SUPPLIER. The field representative shall submit a resume for approval before startup
assistance can be provided. For each training event two separate pre-startup training
sessions shall be performed, one in the early morning and one in the late afternoon. Two
separate post-startup training sessions shall be performed, one in the early morning and one
in the late afternoon. CONTRACTOR shall coordinate the scheduling of such training and
startup assistance with OWNER’S personnel. A typed outline shall be handed out at each
training session and, at a minimum, will include normal operating parameters, alarms, and
maintenance.
EQUIPMENT SUPPLIER shall maintain a complete stock of spare parts commonly needed for
the equipment specified at a location within 500 miles of Corpus Christi, Texas, or shall
furnish spare parts within 48 hours of request.
Qualifications: Equipment shall be the product of anEQUIPMENT SUPPLIER having at least
twenty (20) similar system installations experience in the United States of the type
proposed, each with a minimum of five (5) years of satisfactory service.
Previous Installations List: A list of similar installations demonstrating the experience
requirement shall be furnished. List shall include EQUIPMENT SUPPLIER name. Each
installation shall include project State, project City, project name, project date, equipment
model number, client name(s), and client phone number(s).
EQUIPMENT SUPPLIER shall furnish all equipment with a stainless steel nameplate securely
affixed in a conspicuous place on the equipment showing the equipment ratings, serial
number, model number, equipment supplier name, and other pertinent nameplate data.
Electrical Components, Devices, and Accessories: UL Listed and labeled as defined in
NFPA70, and marked for intended location and application.
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The EQUIPMENT SUPPLIER shall provide an installation report prior to final acceptance. In
addition to the requirements of Section 01 33 10, “Submittal Procedures”,the equipment
installation report shall state that the treatment system is achieving the specified removal
efficiencies. Test data on the installed system shall be included in the report.
Materials Testing: Materials employed in items fabricated of fiberglass reinforced plastic
shall be capable of withstanding maximum calculated stresses that may occur during
fabrication, installation and continuous operation, with allowance for an adequate safety
factor. To confirm materials properties, tests shall be conducted by an independent,
qualified testing laboratory on representative material samples in accordance with the latest
revision of Standards referenced in Paragraph 1.2.B, above.
EQUIPMENT SUPPLIER’s installation report is required prior to final acceptance.
Excessive vibration of equipment while operating shall be cause for rejection. This is based
upon “IN” readings on the fan bearings at installation fan rpm per the requirements of Fan
Application Category BV-3 of AMCA ANSI Standard 204-96. If Final Trim Balancing is
required, it is the responsibility of the EQUIPMENT SUPPLIER to have this done by a
manufacturer approved Vibration Specialist.
Each major equipment item shall have an engraved stainless steel manufacturer’s nameplate
securely affixed in a conspicuous place on the equipment showing the ratings, serial
number, model number, manufacturer, and other pertinent nameplate data.
If the equipment being offered differs from these specifications, all revisions in the design
and construction of the structure, piping, appurtenant equipment, electrical work, etc.
required to accommodate such a substitution shall be made at no additionalcost to the
OWNER.
Factory Test Reports with curves, vibration, sound, pressure, and bearing analyses shall be
provided by the EQUIPMENT SUPPLIER (AMCA 210 and 300).
A power consumption test will be used to verify the bid power consumption.Refer to
specification Section 00 73 00, “Supplementary Conditions”,for additional information.
Where indicated in the Drawings and this Section, all Type 316 stainless steel materials shall
include the following components:
Molybdenum: 2 –3%
Chromium: 16 –18%
Nickel: 10 –14%
1.6DELIVERY, STORAGE, AND HANDLING
Deliver, handle, and store all components to be installed under this section in accordance
with the EQUIPMENT SUPPLIER’s written Pre-Installation Delivery, Storage, and Handling
Instructions and the requirements of Section 01 60 00 “Product Requirements.”
EQUIPMENT SUPPLIER shall be responsible for safe transportation, storage, and handling of
the equipment.
EQUIPMENT SUPPLIER shall protect all flange faces and the more fragile appurtenances of
the sub-assemblies, with padding between pieces in order to prevent one piece from
impacting with another, and by crating or other means for shipment.
Large sub-assemblies shall be supported during unloading to prevent excessive deflection
and overstressing.
Suction and discharge ports shall be protected against entry of foreign objects.
Motors shall be stored as indicated in Section 26 20 00.01 “NEMA Frame Induction Motors,
600 Volts and Below.”
1.7SITE CONDITIONS
The equipment, sizes, materials, and arrangements described in this section are based on
recommendations by equipment suppliers and shall be considered minimum limits of
acceptability. The EQUIPMENT SUPPLIER shall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
Environmental Conditions:
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All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipal wastewater treatment plants.
All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 110°F.
Equipment shall be compatible with heat tracing and insulation, which will be
furnished and installed by the CONTRACTOR. If additional freeze protection beyond
heat tracing and insulation is required it shall be furnished by the EQUIPMENT
SUPPLIER. EQUIPMENT SUPPLIER shall coordinate with the CONTRACTOR to provide
direction on where heat tracing is required, and shall verify that the CONTRACTOR
has provided adequate heat tracing and insulation during startup activities.
1.8WARRANTY
Extended Equipment Warranty: Refer to Section01 78 36,“Warranties”,for extended
equipment warranty.
All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
1.9EQUIPMENT INSPECTIONS
A thorough inspection of each piece of equipment shall be conducted by the CONTRACTOR
upon arrival at construction site to inspect for damage incurred in transit. Any damage shall
be immediately repaired by respective equipment fabricator's personnel, nota sales
representative, or the equipment shall be returned to the EQUIPMENT SUPPLIER.
1.10EQUIPMENT FABRICATION
FRP equipment and accessories shall be fabricated in a heated and well ventilated structure
protected from weather and temperature extremes. Entire fabrication, curing and assembly
process of any piece of FRP equipment shall be indoors. EQUIPMENT SUPPLIER shall submit
an affidavit certifying that all FRP equipment shall be fabricated, cured and assembled as
described in this Section and in accordance with the manufacturer’s recommendations.
1.11EQUIPMENT DEFECTS
Equipment that has mechanical defects and does not meet EQUIPMENT SUPPLIER's
vibration requirements shall be rejected and shall be replaced at EQUIPMENT SUPPLIER’s
full expense for furnishing, installing, removal, and replacement.
Mechanical defects shall include excessive vibration, improper balancing of rotative parts,
improper tolerances, binding, excessive bearing heating, defective materials, improper fitting
of parts, and any other defect which shall in time damage the equipment or impair its
operation.
Requirements must be met concerning minimum and maximum dimensions and the
specifications for materials. If it is found upon delivery that materials do not agree with the
requirements of these Specifications as to materials, size, type, quality, or metallurgy, they
shall be rejected as unfit for use.
PRODUCTS
2.1ACCEPTABLE PRESELECTED EQUIPMENT SUPPLIERS
Subject to compliance with the Contract Documents, the following equipment suppliers are
acceptable.
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Hartzell.
Howden.
No like, equivalent, nor “or-equal” item or substitution is permitted.
2.2ODOR CONTROL FANS
General: Refer to schedule at end of this specification for specific fan requirements.
Provide each odor control fan complete with motor, drive, guard, and baseplate. The fan
shall be constructed such that all surfaces in contact with the corrosive gas stream are to be
made of solid, corrosion resistant fiberglass reinforced plastic (FRP) for the fan housing and
FRP for the fan wheel. All nuts, bolts and fasteners in contact with the gas stream shall be
Type 316 stainless steeland encapsulated in FRP. AMCA Arrangement 4, which places the
motor shaft in the corrosive gas stream, is unacceptable.
Type: Single width, single inlet, backward curved type impeller, minimum Class II
centrifugal fan with fixed discharge. Each fan shall be tested and rated in accordance with
ASHRAE 51-75, AMCA Standard 210 and shall be licensed to bear the AMCA 211-94 Certified
Ratings Seal for air performance and be guaranteed by EQUIPMENT SUPPLIER to deliver
rated performance.
Performance: Fan ratings shall be based on tests made in accordance with AMCA Standard
210 and licensed to bear the AMCA Certified Ratings Seal for Air Performance. Fans not
licensed to bear the AMCA Seal for performance shall be tested, at EQUIPMENT SUPPLIER’s
expense, in an AMCA Registered Laboratory. Fans shall have a sharply rising pressure
characteristic extending throughout the operating range to assure quiet and stable
operation. Fan brake horsepower shall be equal to or less than the BHP specified in the
schedule at the listed static pressure and CFM.
Sound: EQUIPMENT SUPPLIER shall provide a sound power level rating for fans tested and
rated in accordance with AMCA Standards 300 and 301. Sound power ratings shall be in
decibels (reference 10-12 watts) in eight octave bands. The maximum sound level shall be
at or below 85 decibels at 5 feet.
Construction: Fan shall be constructed in accordance with the ASTM D-4167 standard
specification for fiber-reinforced plastic fans and fans to ensure structural integrity. All parts
exposed to the gas stream shall be constructed of, or encapsulated in, an FRP laminate
capable of resisting continuous airstream temperatures of 250°F. Fan housing must be
fabricated of polyester resins; and “C” grade or better surface veil; To prevent premature
deterioration of airstream components a Hartkoate abrasive/erosive resistant coating of 50-
60 mils thickness shall be applied or an equivalent coating.
Housing: Fan housing shall be designed so that air leakage through joints and seals
is negated. All bolted pieces shall be EPDM gasketed for air tightness. Fan housing
shall be made of FRP construction and electrically grounded.
Fan Wheel: Fiberglass construction, backward curved wheel, non-loading, high
efficient, one-piece, resin transfer mold. An assembly of component-type wheel is not
acceptable.
Fan Shaft: Shaft shall be of Type 316 stainless steel or fiberglass designed to operate
25% below first critical speed. Shaft and impeller shall be electromechanically,
statically and dynamically balanced to the requirements of Fan Application Category
BV-3, AMCA 204 and shall receive an operational test prior to shipment. Provide
Teflon or equivalent double lip seal with Type 316 stainless steel mounting plate
between shaft and housing. Seal shall positively prevent liquid and gas leakage.
Fan Bearing Base: Provide Type 316 stainless steel fan bearing base.
Fan Bearings:
Each fan shaft shall be supported by approved, grease lubricated, self-aligning
ball or roller bearings made of vacuum degassed 52100 steel. Ball or roller
bearings shall be made by manufacturers who are members of the American
Bearing Manufacturers Association (ABMA) and shall be selected for a minimum
rating life (L-10) of 100,000 hours at the fans maximum rated speed and based
on Basic Dynamic Load Ratings calculated from ABMA formulas (ABMA
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Standards, Section No. 9, and Section No. 11, Latest Revisions). Material
factors used in formula calculations shall be based on values assuming a
conventional good quality, hardened bearing steel without benefit of vacuum
degassing. Specifically, for pound and inch units, factor "f" shall be as given in
the tables of ABMA Standards cited above.
The operating internal temperature of ball bearings with ambient temperature
of 80°F shall not exceed 200°F. Temperature measurements shall be made
with a thermal imaging thermometer. (Thermometers shall have an accuracy
at 130°F of ±2°F). Where thermometer wells are not provided or required, the
surface temperature of the bearing housing shall be measured by a thermo-
meter pressed firmly against the surface and sealed with a suitable plastic
putty. Temperature readings during inspection and start-up after 3 hours of
run time that exceed 140°F as measured by the thermometer-surface method,
shall be deemed presumptive evidence that the operating internal temperature
of the bearings exceed 200°F, unless EQUIPMENT SUPPLIER can conclusively
prove otherwise with a bearing temperature analysis to the satisfaction of the
OWNER or OWNER’S representative. In the absence of such proof, it shall be
incumbent to reduce the temperature at or below 140°F with no additional cost
to the OWNER.
Bearing temperature shall not exceed 225°F at the fan’s maximum rated speed.
Computations on bearing selection shall be submitted for approval and shall
show complete details of loading. A dynamic factor of 2.0 shall be applied to
loading. Ball and roller bearings shall be enclosed in oil-tight housings
equipped with approved shaft seal rings and shall be suitably arranged for high
pressure grease lubrication.
The bearing supports for the shaft shall be of rigid design and shall be securely
fastened to the base to ensure the proper alignment of the main shaft
bearings. Bearings located in the corrosive gas stream are not acceptable.
Bearings shall be factory lubricated with a premium quality NLGI 2 or 3-grade
multi-purpose ball bearing grease having corrosion inhibitors, anti-oxidant
additives and mechanical stability for high speed operation. Bearing grease
shall be multi-purpose lithium soap grease. The grease shall also have a
minimum base oil viscosity of 500 SUS at 100°F and shall be suitable to
operate continuously at 225°F. Heavy, long fibered greased will not be
acceptable for use in bearings.
Product and Manufacturer: Provide bearings as manufactured by one of the
following:
Link Belt
Fan impeller and driving pulley shall be secured to shaft with keys and set screws.
Fan housing shall have flanged discharge and inlet drilled connection and companion
flanges (ANSI dimensions). Fan shall be separated from ductwork at inlet and outlet
by flanged flexible connections. CONTRACTOR shall coordinate flange drilling with
duct.
Stainless steel nameplates giving the name of the manufacturer, serial number, model
number, rated capacity in cfm, head in inches of water (gage), fan in rpm, and any
other pertinent data shall be permanently affixed to each fan with stainless steel
hardware.
Fan Motors:
Comply with NEMA designation, temperature rating, service factor, enclosure
type, and efficiency requirements for motors specified in Section 26 20 00.01,
“NEMA Frame Induction Motors, 600 Volts, andBelow” for motors, 600 volts
and lower, and 250 HP and smaller. Requirements of this Section supersede
any conflicting requirements of Section26 20 00.01, “NEMA Frame Induction
Motors, 600 Volts, andBelow.”
Motor Sizes: Properly size so that enough driven loads will not require the
motorto operate in service factor range above 1.0 along the complete
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operating range. Motor sizes listed in equipment data sheets at the end of the
Section shall be confirmedfor compliance with this requirement.
If a motor horsepower rating larger than specified is offered as a substitute and
accepted, provided required changes in conductors, motor controllers, overload
relays, fuses, switches and other related items with no change in the Contract
price.”
Refer to the equipment data sheets at the end of the Section for detail motor
requirements.
Motors shall be rated for Class I, Division II locations.
Motors shallbe in accordance with all current applicable standards of NEMA,
IEEE, AFBMA, NEC, ANSI and NFPA 820.
Motors shallbe normal starting torque, normal slip, squirrel cage induction
type.
Motor thrust bearings shallbe adequate to carry continuous thrust loads under
all conditions of fan operation.
Motor efficiencies shallbe determined in accordance with NEMA Standard MG1-
12.53a and IEEE Standard 112, Test Method B. Nominal and guaranteed
efficiencies shallbe included on motor nameplates in compliance with NEMA
Standard MG1-12.53.b.
Stainless steel nameplates giving the name of the MANUFACTURER, serial
number and all data shallbe permanently attached to each motor.
Access Doors: Raised, bolted type, held in place with Type 316 stainless steel bolts with
gaskets. Bolts shall be embedded and encapsulated in FRP housing.
Odor control fan mounting shall be AMCA standard Arrangement 10 up to 15 horsepower,
20 horsepower and above shall be Arrangement 1 with fabricated Type 316 Stainless Steel
Channel Sub-base and slide rail type motor mounting. Fan base shall be bolted directly to
equipment slab and shop painted with an epoxy coating for outside/corrosive application.
Drains: The fan shall be properly sealed to prevent condensate leaks and shall be provided
with a condensate drain. Provide drains at low point of scroll, minimum 1-inch pipe coupling
welded to housing with threaded corrosion resistant plug. CONTRACTOR shall install a trap
in the drain of necessary length to prevent foul air from blowing into the drain system.
Drive: Matched V-belts and adjustable sheave pulleys shall be cast steel or cast iron, sized
for 1.5 service factor.
Belt and Shaft Guard: Type 316 stainless steel construction epoxy painted with tachometer
hole, OSHA approved. Provide shaft and bearing guard.
The field installed and operating fan inboard and outboard bearing motions shall not exceed
the in-situ operation levels for Fan Application Category BV-3 of ANSI/AMCA 204-96. The
instrument system used must have a flat response down to 120 rpm. EQUIPMENTSUPPLIER
Field Representative shall measure the vibrations after start-up in the presence of the
OWNER’S representative.
Fan vibrations that exceed the ANSI/AMCA 204-96 in-situ operation levels, as described
above, during operation in the warranty period shall be reduced by EQUIPMENT SUPPLIER
Field Representative. EQUIPMENT SUPPLIER Field Representative can choose to
dynamically balance the fan in place using a recognized specialist, replace bearings or make
structural modifications to reduce the vibrations, as approved by the OWNER.
EQUIPMENT SUPPLIER shall furnish and install a sticker identifying the fan maximum
operating speed. Speed changes that exceed this value are not permitted.
Inlet Vane Damper
Furnish and install a Type 316 stainless steel manually operated multiple blade inlet
vane damper on the suction side of each odor control exhaust fan.
Rated for air velocities up to 6,000 fpm.
Materials of Construction:
Frame: Type 316 stainless steel min. 10 ga. channel.
Blades: Type 316 stainless steel min. 10 ga.
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Bearings: Relubricable ball, mounted externally with stainless steel sleeve
bearings and stainless steel thrust washers at hub and frame.
Axles: Type 316 stainless steel full length rod.
: Type 316 stainless steel. Swivels and bearings are epoxy coated steel.
Hub: Type 316 stainless steel flat panel.
Operating Lever: Lever arm with locking manual quadrant Type 316 stainless
steel construction.
Ends: Flanged with bolt holes drilled to match fan inlet.
Manually operated with quadrant locking mechanism.
Provide Type 316 stainless steel nuts, bolts and washers for flanged connections to
fan and fan inlet box or flexible connector flange as required.
Mill Finish –No painting.
Provide damper open limit switch for fan starter logic. The switch shall be minimum
2A dry contactor.
Product and Manufacturer: Provide one of the following:
Swartout, Model 851FG.
Ruskin, Model HD-IVD.
Or approved equivalent.
Flanges shall be glass fiber reinforced, compatible with the duct material provided, and have
a chemical resistance greater than or equal to the duct material. Flanges shall comply with
PS-1569, Table 5, at a design pressure of 25 psi, and have a minimum of ANSI/ASME B16.1,
Class 25 diameter and drilling.
Coatings:
Baked epoxy phenolic or “cold set” epoxy-phenolic amine cured, brush or spray coats
in accordance with EQUIPMENT SUPPLIER’s specifications.
Operation and Controls: The operation and controls shall be provided as required to furnish
the complete OCS specified in Section 44 31 11, “Biological Tower-Type Odor Control
System.”
A selector switch shall be provided for each foul air fanwith LOCAL/OFF/REMOTE
operation options. Each selector switch shall be integrated into the Odor Control
Panel, which is described in Section 44 31 11 “Biological Tower-Type Odor Control
System.”
LOCAL allows the fan to be run from the Plant Control System.
OFF turns the fan off.
REMOTE allows the fan to be run in automatic mode. Local control shall be
included, so the foul air fan can be manually adjusted when in REMOTE
operation.
Each foul air fan shall have an LED indicator light(s) to indicate the current fan
operational status.
Contractor shall provide bubble-tight damper at foul air fan outlet, as shown on the
Drawings. Bubble-tight dampers at the foul air fan outlet shall be equipped with an open
limit switch for fan start logic. The switch shall be minimum 2A dry contactor.
All fasteners (nuts, bolts and washers) used for Odor Control Fans shall be Type 316
stainless steel.
Odor Control Fans shall be located in outdoor and corrosive areas. All mechanical and
electrical equipment and material shall conform to NEMA 4X, non-metallic requirements.
Provide panels with a three-point latch door system. Mounting hardware shall be Type 316
stainless steel including fasteners and unistrut.
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2.3FINISHES
All gears, bearing surfaces, machined surfaces and other surfaces which are to remain
unpainted shall receive a heavy application of grease or other rust/corrosion resistant
coating. The coating shall be maintained during storage and until the equipment isplaced
into operation.
EQUIPMENT SUPPLIER shall certify, in writing, that the shop primer and shop finish coating
system is compatible with intended outside / corrosive application as shown on the Contract
Drawings. A corrosive atmosphere of hydrogen sulfide and dilute sulfuricacid are expected
to be present.
2.4ACCESSORIES
Anchor Bolts: Provide template and Type 316 stainless steel anchors and fasteners in
accordance with Section 05 05 23 “Metal Fastenings and Anchor Bolts”, as shown on the
Drawings, and as recommended by the EQUIPMENT SUPPLIER. Size and locations as
required by EQUIPMENT SUPPLIER. EQUIPMENT SUPPLIER shall size all anchor bolts and
fasteners required of ample size and strength for the intended purpose, minimum of ½-inch
diameter. Fastener sizing calculations shall be provided as an informational submittal.
CONTRACTOR shall furnish and install all anchor bolts and fasteners in accordance with the
EQUIPMENT SUPPLIER’s installation instructions.
Equipment Identification Plates: EQUIPMENT SUPPLIER shall furnish a 16-gauge stainless
steel identification plate securely mounted on the equipment in a readily visible location. The
plate shall bear 1/4-inch die-stamped equipment identification number indicated in this
Section and/or on the Drawings.
Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 60
pounds shall be provided with lifting lugs.
An in-line grease filter shall be provided upstream of each foul air fan.
Initial Supply of Lubricants: EQUIPMENT SUPPLIER shall indicate types, brands, and
quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants and shall comply with all
EQUIPMENT SUPPLIER recommended procedures.
All equipment shall be installed with Type 316 stainlesssteelfasteners.
2.5TOOLS, SPARE PARTS, AND MAINTENANCE MATERIALS
General: EQUIPMENT SUPPLIER shall furnish all special tools that are required to assemble,
disassemble, repair, and maintain any item of mechanical equipment, with respective
equipment. Special tools shall include any type of tool that has been specifically made for
use on an item of equipment for assembly, disassembly, repair, and maintenance. When
special tools are provided they shall be marked or tagged, and a list of such tools shall be
included with maintenance and operation instructions describing use of each marked tool.
Additional requirements shall be included with individual items of equipment.
Furnish and deliver the following spare parts for each fan size.
Two (2) sets of spare belts.
Two (2) sets of bearings.
Two (2) replacement Teflon seals.
Furnish list of solvents for cleaning dirt, grease and oil from surface of non-metallic parts.
Spare parts shall be packed in sturdy containers with clear indelible identification markings,
referencing the equipment that they are intended for, and shall be stored in a dry, warm
location until transferred to the OWNER at the conclusion of the project. Provide complete
ordering information including manufacturer, part number, part name and equipment for
each part to be used. Each part shall be labeled with part numbers which correspond to the
Operation and Maintenance Data submitted in accordance with Section 01 78 23,“Operation
and Maintenance Data.”
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EXECUTION
3.1PREPARATION
EQUIPMENT SUPPLIER shall assure that all equipment furnished under this Section is
suitable for installation as specified. The EQUIPMENT SUPPLIER is responsible for
determining the necessary clearances and headroom required to move all equipment to its
final location.
3.2INSTALLATION
EQUIPMENT SUPPLIER shall verify installation and test all odor control fan equipment.
EQUIPMENT SUPPLIER’s installation report shall be required prior to final acceptance.
Odor control fan equipment shall be installed as specified herein and as shown on Drawings,
and in accordance with the EQUIPMENT SUPPLIER's recommendations and instructions.
Equipment shall be installed in such a manner that connecting piping shall not impose any
strain whatsoever on any equipment. Equipment shall be set upon grouted foundations,
level or perpendicular, as the case may be, so that connecting flanges, screwed connections,
or flexible connections shall meet without strain or distortion. Base leveling nuts shall be
blocked out during grouting of foundations, the grout allowed to set for not less than three
days, leveling nuts loosened and followed by grouting of block-outs, with non-shrink grout.
All equipment shallbe installed with Type 316 stainlesssteelfasteners.
EQUIPMENT SUPPLIERshallassure that all equipment furnished under this Section is
suitable for installation as specified. The EQUIPMENT SUPPLIERis responsible for
determining the necessary clearances and headroom requiredto move all equipment to its
final location.
In every case where a drive motor is connected to a driven piece of equipment by a flexible
coupling, the coupling halves shall be disconnected and alignment between motor and
equipment checked and corrected. Machinery shall first be perfectly aligned and leveled by
means of Type 316 stainless steel wedges and shims near anchor bolts. Anchor bolts shall
be tightened against shims on wedges and equipment shall again be checked for level and
alignment before placing grout.
Equipment bases shall not be grouted nor foundation bolts finally tightened until all piping
connections are complete and in satisfactory alignment with no strain transmitted to the
equipment.
Examine pads or supports to receive odor control fans for:
Proper anchor bolt locations.
Unevenness, irregularities and incorrect dimensions.
Supervise installation in accordance with odor control fan manufacturer's instructions and
recommendations.
Provide flanged flexible connections at air inlet and discharge of odor control fans.
All equipment shall be installed on concrete bases and secured with anchor bolts in
accordance with the EQUIPMENT SUPPLIER's recommendations. CONTRACTOR shall
accurately shim base to grade and spaces between shims filled with an approved non-shrink
grout. After grout has reached its initial set, exposed edges shall be cut back 1/2-inch and
edges neatly finished with 1:2 cement mortar.
EQUIPMENT SUPPLIER shall include furnishing and applying an initial supply of grease and
oil, recommended by the respective manufacturer.
Connect all piping, valves, and accessories as necessary to complete the installation.
Install all conduit and wiring and complete all connections.
3.3FIELD / SITE QUALITY CONTROL
EQUIPMENT SUPPLIER Services
EQUIPMENT SUPPLIER Field Representative: Manufacturer’s service person for areas
where the odor control fans are installed to assist in the installation of the equipment,
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0537-038-01FOUL AIR FANSJANUARY 2023
check the installation before it is placed into operation, assist in the performance of
field vibration tests, supervise initial operations, and instruct the plant operators in the
care, operation and maintenance of the equipment.
Service person shall verify that lubrication systems are complete, clean and filled with
the proper grade of lubricants.
Reports: EQUIPMENT SUPPLIER shall submit a report by service person of each visit
to the site. Reports shall provide complete information on time, schedule, tasks
performed, persons contacted, problems corrected, test results, training, instruction
and all other pertinent information.
Training: In addition to above requirements, furnish services to instruct and train
plant operators in the proper care, operation and maintenance of equipment.
Additional Inspections -Twelve (12) months after acceptance of the odor control
fans, the manufacturer's factory trained service person shall perform an inspection of
the system and submit an inspection report to OWNER.
Table 1: Manufacturer Field Services
No.
Person No. Trips
Work DescriptionDays
Installation assistance and inspection11
Functional and performance testing11*
Pre-startup classroom or site training11
Facility startup and field vibration testing11*
Follow up visit 12 months after substantial
11
completion for inspection and training
INSPECTION OF ODOR CONTROL FANS
OWNER or OWNER’S representative reserves right to reject any and allitems of
equipment found to have following: blisters, chips, crazing, exposed glass, dry cracks,
burned areas, dry spots, foreign matter, or entrapped air at the laminate surfaces
which does not satisfy the tolerances specified in ASTM D 2563 Table 1, Acceptance
Level II for inside and outside surfaces or meet the specified requirements.
INSPECTION AND START-UP ADJUSTMENTS
The EQUIPMENT SUPPLIER Field Representative shall perform the following
inspection of equipment with the Owner’s Representative.
Verify proper equipment mounting and setting.
Verify that control, interlock and power wiring is complete.
Verify alignment of each motor and drive.
Verify proper piping connections and accessories.
Verify that lubrication is completed.
Verify direction of rotation.
Verify setting of safety controls.
Monitor heat buildup in bearings.
Check motor loads against nameplate data.
Verify proper starter overload heater sizes.
Verify function of safety and operating controls.
Verify proper operation of equipment.
Remove all loose materials and obstructions from interior of ducts and fans.
Remove debris and waste materials resulting from installation.
The EQUIPMENT SUPPLIER shall conduct the following Start-up Adjustments:
Adjust fan for proper alignment and flow.
Set volume control devices for approximate positions in preparation for final
testing and balancing.
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Balance system for CFM provided on the Drawings and in accordance with this
section.
FIELD TESTS
After EQUIPMENT SUPPLIER and OWNER’S representative have mutually agreed that
the equipment installation is complete and ready for continuous operation,
EQUIPMENT SUPPLIER Field Representative shall conduct an operating test of the
equipment and controls in the presence of OWNER or OWNER’S representative to
demonstrate that the equipment and its controls shall function correctly.
EQUIPMENT SUPPLIER Field Representative shall perform standard AMCA tests 210
and 300, as a minimum.
3.4CLOSEOUT ACTIVITIES
A copy of all information from functional tests including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
3.5SUPPLEMENTS
The following table is included after “End of Section” and is considered part of this Section:
Table 2 –Foul Air Fan Design Details
END OF SECTION
Table 2 –Foul Air Fan Design Details
Number Provided 2
Fan Designation FAB-4301, FAB-4302
Elevation, MSL 11.83
Service Foul Air
Ambient Temperature Range 10 -120°F
Present Capacity
Design Flow Rate2,700cfm
Static Pressure*9.8in w.c.
Maximum Speed2,000 rpm
Maximum Outlet Velocity2,600 fpm
Motor
HorsepowerNote 1
Voltage/Phase/Hz480/3/60
TypeClass I, Div II, Severe Duty
Wheel Diameter Note 1
Arrangement Note 1
Rotation As shown on the Drawings
Discharge Clockwise Up Blast
Note 1: As determined by EQUIPMENT SUPPLIER
* Static pressure includes 0.7” w.c. for the ductwork (inlet and interconnecting), 3.5” w.c. for the
bioscrubber,and 5.6” w.c for the carbon adsorber, which is preliminary. Prior to preparing shop
drawings, static pressure shall be confirmed by the EQUIPMENT SUPPLIERbased on the Final Design
Drawings.
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F:\\PROJECTS\\0537\\038-01\\9 DESIGN\\9-4 SPECIFICATIONS\\CONFORMED\\43 11 19 FOUL AIR FANS.DOCX
SECTION 43 21 39
PUMP, HORIZONTAL DRY PIT SUBMERSIBLE -CENTRIFUGAL
GENERAL
1.1SUMMARY
Section Includes:
Horizontal dry pit non-clog submersible centrifugal pumps having semi-open multi-
vane back swept, screw-shaped impeller for:
Return Activated Sludge (RAS) Pumps to be installed at the RAS-WAS Pump
Station for pumping RAS from Secondary Clarifier No. 1 and 2 to the Aeration
Basin RAS Splitter Box. The RAS-WASPump Station is located outdoors, in a
dry pit, with no canopy.
Installation, startup, testing, and placing in service assistance.
Scope of Work:
Furnish, install, test and place in operation 4 (four) pumping units at the RAS-WAS
Pump Station(BRD-RAS-PMP11, -PMP12, -PMP21, -PMP22).
Equipment Manufacturer shall be responsible to coordinate the testing and installation
of the pumping units and for the adequacy and compatibility of the pump, motor and
CONTRACTOR furnished VFD.
General Requirements:
Equipment Manufacturer shall furnish all equipment and provide assistance to the
CONTRACTOR during equipment installation, check-out, startup, testing and
commissioning of the horizontal dry pit non-clog submersible centrifugal pumps, with
side inlets and top discharge, complete with motors, and all necessary, pump
supports, anchors, brackets, and accessories, and other manufacturer furnished items
herein specified for a complete operating system. Pumps to be compatible with new
CONTRACTOR furnished VFDs.
Design Requirements:
All equipment including controls and drives specified herein shall be specifically
designed for wastewater sludge pump station service and the environment
encountered in this installation.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipal wastewater treatment plants. This is a
coastal environment, so high levels of chlorides will be present.Pumps will be located
outdoors and shall be designed and capable of operation at ambient temperature of
10°F to 110°F.
Equipment shall be designed and capable of either continuous or intermittent
operation receiving mixed liquor from the secondary clarifiers.
Grit and other abrasive materials should be expected to be present as should
rags, large solids, and stringy material. The presence of these items will not be
considered as abnormal, unanticipated or abusive with regard to the equipment
operation and warranty.
The equipment must operate over the specified flow range without rags and stringy
material accumulating in the pump and clogging it.All equipment, supports, anchors
and fasteners shall be Type 316 stainless steel and be of adequate strength to
withstand loads associated with starting, turbulence, thrusts from liquid movement,
thermal expansion and contraction and other loads encountered under normal
operating conditions.
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The equipment, sizes, materials, and arrangements described in this specification
section are based on recommendations by equipment manufacturers and shall be
considered minimum limits of acceptability. The equipment manufacturer shall be
responsible for design, arrangement, and performance of all equipment supplied
under this section. Arrangements other than those shown on plans shall be subject to
ENGINEER's approval.
The general arrangement of the piping and pumps are shown on the plans. Pump
design parameters are listed in the Pump Data Sheets at the end of this section.
1.2REFERENCES
Drawings and general provisions of the Contract, including Special Conditions and Division 1
Specification Sections, apply to this Section.
References: Following is a list of standards, which might be referenced in this Section:
American Bearing Manufacturer’s Association (ABMA)
9 -Load Ratings and Fatigue Life for Ball Bearings
11 -Load Ratings and Fatigue Life for Roller Bearings
Refer to specification Section 43 22 10 “Common Requirements for Pumps” Paragraph
1.3.
Related Sections:
Section 01 33 00 “Submittal Procedures”
Section 05 05 23 “Metal Fastenings and Anchor Bolts”
Section 09 91 00 “Painting and Protective Coatings”
Section 26 20 00.01 “NEMA Frame Induction Motors, 600 Volts and Below”
Section 43 22 10 “Common Requirements for Pumps”
1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Product Data: Include construction details, material descriptions, dimensions of individual
components and profiles, rated capacities, operating characteristics, electrical
characteristics, and furnished specialties and accessories.
Shop Drawings: Include plans, elevations, sections, details, and attachments to other work.
Detail equipment assemblies and indicate dimensions, weights, loads, required
clearances, method of field assembly, components, and location and size of each field
connection.
Performance data curves showing head, capacity, horsepower demand, and pump
efficiency over the entire operating ranges of the pump, from shutoff to maximum
capacity.
Wiring Diagrams: If applicable, for power, signal, and control wiring diagrams,
including terminals and numbers.
Complete motor nameplate data, as defined by NEMA, motor manufacturer, and
include any motor specifications.
Documentation demonstrating factory finish is equivalent to finish system specified in
this Section.
Information Submittals:
Factory functional and performance test reports and logs.
Manufacturer’s Certification of Compliance.
Special shipping, storage and protection, and handling instructions.
Manufacturer’s instructions for installation.
Manufacturer’s Certificate of Proper Installation.
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Qualification Data: For manufacturer and manufacturer’s representative.
Suggested spare parts list to maintain the equipment in service for a period of two
years. Include a list of special tools required for checking, testing, parts replacement,
and maintenance with current pricing information.
List special tools, materials, and supplies furnished with equipment for use prior to
and during startup and for future maintenance.
Warranties and service agreements.
Operation and Maintenance Data:
Provide for each pumping system in accordance with Section 01 78 23 “Operation and
Maintenance Data.”
1.5QUALITY ASSURANCE
Refer to specification Section 43 22 10 “Common Requirements for Pumps” Part 1.5.
Field Representative: The EQUIPMENT SUPPLIER shall furnish a qualified field representative
for the time indicated in Paragraph 3.7.A of this Section. Field representatives shall be
factory-employed personnel and have a minimum of two (2) years of experience with the
operation of and training on this type of equipment. Sales representatives will only be
considered acceptable service technicians if they have three (3) years of experience with the
operation of and training on this type of equipment from the EQUIPMENT SUPPLIER being
supplied and have started up 15 units of a similar size and type from the EQUIPMENT
SUPPLIER. The field representative shall submit a resume for approval before startup
assistance can be provided. For each training event,two separate pre-startup training
sessions shall be performed, one in the early morning and one in the late afternoon. Two
separate post-startup training sessions shall be performed, one in the early morning and one
in the late afternoon. CONTRACTOR shallcoordinatethe scheduling of such training and
startup assistance with OWNER’S personnel. A typed outline shall be handed out at each
training session and, at a minimum, will include normal operating parameters, alarms, and
maintenance.
Qualifications: Equipment shall be the product of an EQUIPMENT SUPPLIER having at least
twenty (20) similar system installations experience in the United States of the type
proposed, each with a minimum of fifteen (15) years of satisfactory service.
1.6DELIVERY, STORAGE, AND HANDLING
Refer to specification Section 43 22 10 “Common Requirements for Pumps” Paragraph1.6.
1.7SITE CONDITIONS
Refer to specification Section 43 22 10 “Common Requirements for Pumps” Paragraph1.7.
1.8WARRANTY
Refer to specification Section 43 22 10 “Common Requirements for Pumps” Paragraph1.8.
PRODUCTS
2.1MANUFACTURERS
Manufacturers: Subject to compliance with requirements, provide products by one of the
following:
Flygt Dry Pit Submersible N3153 with N-Series Impeller
KSB Model KRT D 200-316/186XFG-DV
6
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2.2PUMP CONSTRUCTION
Design:
Pump Type: Horizontal dry pit submersible as indicated on the Drawings and the
Pump Data Sheet.
Basic Design: Single-passage, clog-free pump, utilizing a semi-open multi-vane
impeller as indicated, intended for services requiring reliable solids handlings,
combined with high efficiency, low required NPSH, and a large solid passage. The
impeller shall be statically and dynamically balanced, capable of mechanical self-
cleaning upon each rotation.
Semi-open non-clogging multi-vane impeller, for high efficiency pumping of municipal
wastewater.
The screw shape of the impeller inlet shall provide an inducing effect for the handling
of up to 5% sludge.
Casing:
Pump Volute and Suction Cover: Cast iron, ASTM A-48, Class 35B.
The pump volute shall incorporate a suction cover insert ring or alternatively, a wear
plate. If an insert ring is used, the volute shall have a replaceable suction cover insert
ring in which are cast spiral-shaped, sharp-edged groove(s). The spiral groove(s) shall
provide trash release pathways and sharp edge(s) across which each impeller vane
leading edge shall cross during rotation so to remain unobstructed. Alternatively, if a
wear plate is employed the wear plate shall incorporate cutting grooves and an
outward spiral V-shaped groove on the side facing the impeller, to shred and force
stringy solids outward from the impeller and through the pump discharge.
The insert ring shall be of ASTM A-532 (Alloy III A) 25% chrome cast ironand provide
effective sealing between the multi-vane semi-open impeller and the volute housing.
The wear plate shall be mounted to the volute with four Type 316 stainless steel
securing screws and four Type 316 stainless steel adjusting screws to permit close
tolerance adjustment between the wear plate and impeller for maximum pump
efficiency. Adjustment to allow for wear and restore peak pumping performance shall
be accomplished using standard tools, and without requiring disassembly of the
pump.
Cooling Jacket:
Each unit shall be provided with an integral motor cooling system. AType 316
stainless steel motor cooling jacket shall encircle the stator housing, providing for
dissipation of motor heat regardless of the type of pump installation. An impeller,
integral to the cooling system and driven by the pump shaft, shall provide the
necessary circulation of the cooling liquid through the jacket. The cooling liquid shall
pass about the stator housing in the closed loop system in turbulent flow providing for
superior heat transfer. The cooling system shall have one fill port and one drain port
integral to the cooling jacket. The cooling system shall provide for continuous pump
operation in liquid or ambient temperatures of up to 104°F (40°C). Fans, blowers or
auxiliary cooling systems that are mounted external to the pump motor are not
acceptable.
Impeller:
Material: High Chrome Iron, minimum 450 BHN, ASTM A532.
Statically and dynamically balanced.
The impeller to volute clearance shall be readily adjustable by the means of a single
trim screw. The impeller shall:
Be locked to the shaft, held by an impeller bolt; or,
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Have a slip fit onto the motor shaft and drive key and be securely fastened to
the shaft by a Type 316 stainless steel bolt which is mechanically prevented
from loosening by a positively engaged ratcheting washer assembly.
The hydraulic design of the multi-channel impeller shall provide a minimum of 2.3
inches of non-compressible solids handling and superior hydraulic efficiency.
Shaft:
Material: Stainless steel,ASTM A479 S43100-Type 420.
Diameter: Sufficient to carry maximum load and prevent vibration and fatigue.
Bearing Assembly:
Bearings:
The integral pump/motor shaft shall rotate on two bearings. The motor
bearings shall be sealed and permanently grease lubricated with high
temperature grease.
The upper motor bearing shall be a two-row angular contact ball bearing to
handle radial loads. The lower bearing shall be a two row angular contact ball
bearing to handle the thrust and radial forces.
Rating Life: Minimum L-10 life 50,000 hours as defined by ABMA Standards.
The pump shaft and motor shaft shall be an integral, one-piece unit adequately designed to
meet the maximum torque required at any normal start-up condition or operating point in
the system.
Shaft Sealing:
Each pump shall be provided with a positively driven dual, tandem mechanical shaft
seal system consisting of two seal sets, each having an independent spring.
The lower primary seal, located between the pump and seal chamber, shall
contain one stationary and one positively driven rotating corrosion and abrasion
resistant tungsten-carbide ring.
The upper secondary seal, located between the seal chamber and the seal
inspection chamber shall be a leakage-free seal. The upper seal shall contain
one stationary and one positively driven rotating corrosion and abrasion
resistant tungsten-carbide seal ring.
The rotating seal ring shall have small back-swept grooves laser inscribed upon
its face to act as a pump as it rotates, returning any fluid that should enter the
dry motor chamber back into the lubricant chamber.
All seal rings shall be individual solid sintered rings.
Each seal interface shall be held in place by its own spring system. The seals
shall not depend upon direction of rotation for sealing.
Mounting of the lower seal on the impeller hub is not acceptable.
Shaft seals without positively driven rotating members or conventional double
mechanical seals containing either a common single or double spring acting
between the upper and lower seal faces are not acceptable.
The seal springs shall be isolated from the pumped media to prevent materials
from packing around them, limiting their performance.
Each pump shall be provided with a lubricant chamber for the shaft sealing system.
The lubricant chamber shall be designed to prevent overfilling and shall provide
capacity for lubricant expansion. The seal lubricant chamber shall have one drain and
one inspection plug that are accessible from the exterior of the motor unit. The seal
system shall not rely upon the pumped media for lubrication.
The area about the exterior of the lower mechanical seal in the cast iron housing shall
have cast in an integral concentric spiral groove. This groove shall protect the seals
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by causing abrasive particulate entering the seal cavity to be forced out away from
the seal due to centrifugal action.
A separate seal leakage chamber shall be provided so that any leakage that may
occur past the upper, secondary mechanical seal will be captured prior to entry into
the motor stator housing. Such seal leakage shall not contaminate the motor lower
bearing. The leakage chamber shall be equipped with a float type switch that will
signal if the chamber should reach 50% capacity.
Pumping Unit Assembly:
Vertical Dry Pit Mounting:
Pump shall be capable of operating in a continuous non-submerged condition in
vertical position in a dry pit installation, permanently connected to inlet and
outlet pipes. Pump shall be of submersible construction and will continue to
operate satisfactorily should the dry pit be subjected to flooding.
Pump shall have a Type 316 stainless steel telescoping inlet pipe to provide access to
the pump suction end without having to dismantle the pump. Pressure gauge
4
connection shall be included standard on telescoping inlet pipe. The volute shall have
a conveniently located drain tube to aid with inspection and or maintenance
operations.
Provide service cart for safe handling during maintenance.
Furnish connection for a casing drain.
2.3FINISHES
All equipment items except stainless steel shall receive surface preparation, prime coating
and finish coating in the factory in accordance with Section09 91 00 “Painting and
Protective Coatings”. Finish coating colors shall be selected by the OWNER from finish color
charts to be provided in shop drawing submittals. Furnish one gallon of touch up paint for
installation CONTRACTOR to apply.
All stainless steel surfaces shall be cleaned and welds shall be brushed with Type
316stainless steel brushes. Electro bead blast or chemically treat all external non-welded
stainless steel to a uniform finish.
Motors and hydraulic units shall have a factory finish.
Machined, polished, and non-ferrous surfaces shall be coated with a corrosion prevention
compoundcapable of withstanding high chloride levels and wastewater conditions.
2.4SOURCE QUALITY CONTROL
Factory Tests and Adjustments: Test all pumping units and control panels to be furnished.
Include test data sheets, curve test results, performance test logs, certified by a
factory test engineer.
Functional Test: Perform motor test on equipment. Include a vibration test, as follows:
Dynamically balance rotating parts of each pump and its driving unit before final
assembly.
Limits:
Complete rotating assembly, including drive unit and motor, shall be less than
90 percent of limits established in the Hydraulic Institute Standards.
Performance Test:
Perform on each pump in accordance with Hydraulic Institute Standards.
Tests shall be sufficient to determine the curves of head, input horsepower, and
efficiency relative to capacity from shutoff to 150% of design flow. A minimum of six
points, including shutoff, shall be taken for each test.
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At least one point shall be obtained as near as possible to each specified condition.
Results of the performance test shall be certified by a Registered Professional
Engineer and submitted for approval prior to shipment.
Hydrostatic Test: Pump casing tested at 150 percent of shutoff head. Test pressure
maintained for not less than five minutes.
2.5MOTORS
Motor and Cable
See Table 1and Table 2at the end of this Section for motor data.
Motor shall be induction type with a squirrel-cage rotor, shell type design, housed in
an air filled, watertightchamber.
The motor shall be designed for continuous duty while handling pumped media.
The stator shall be press fitted or heat-shrink fitted into the stator housing. The use
of fastening devices that penetrate the stator housing are not acceptable.
The motor stator shall be insulated with moisture resistant Class H insulation.
Motor shaft shall be one-piece, solid, Type 431stainless steel. Carbon steel shafts or
shaft sleeves are not acceptable. Shaft shall be sufficient to transmit full driver output
with a maximum deflection of 0.002 inches measured at the lower mechanical seal.
Rotor is to be dynamically balanced to meet NEMA vibration limits; all external
hardware is to be stainless steel.
The power cable shall be suitable for a continuous submersible application and sized
in accordance with NEC requirements. Cable leads are to enter at the top of the
motor, and are to allow the cable-to-motor connection to be accomplished in the field
with by the manufacturer or pump service company, or the use of an epoxy sealed
entry system. Motor power lead wires shall be permanently and thermally connected
to the stator for structural strength. Motor lead wires shall be connected to the power
cable in a watertight chamber and appropriate watertight seal cable entrance. Pump
motor power cable shall be oil and watertight, rated for continuous submerged
service. Cable conductors shall be copper, sized,and rated per NEC. Cable shall be
sized using 125 % of motor nameplate. Motor control conductors for thermal and
moisture leak sensory shall be rated for continuous submerged service and shall be
run in a separate jacketed cable and conduit from the power cable. Power cable shall
include a dedicated ground conductor. All conductors shall be permanently identified
at both ends. Power/control cable shall be a minimum of 130 feet in length for Design
to allow required power and control termination.
Power and control leads shall be O-ring sealed.
All O-rings shall be Nitrile rubber O-rings.
Pump(s) shall be provided with a mechanical seal system consisting of two totally
independent seal assemblies. The seal shall be a double mechanical seal in a cast iron
seal housing constructed in two sections with a registered fit. The seal shall be
constructed of tungsten carbide or silicon carbide. The upper and lower seal
assemblies shall operate in a lubricant reservoir that lubricates the lapped seal faces
at a constant rate.
A mechanical seal leakage system shall be included in each motor. Mechanical seal
system shall be monitored for leaking during pump operation and standby time. If
sufficient water enters the motor the mechanical seal leakage system shall send a
signal to the control panel and shut down the pump.
The motors shall be provided with motor thermal switches embedded in the windings
to protect the motor from burnout due to excessive heating.
Inrush on starting shall be no more than allowed by NEC Code Letter G (5.6 KVA/HP)
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The motor and cable on each pump shall be tested for moisture content or insulation
defects. After the test, the pump cable end shall be fitted with a shrink-fit rubber
boot to protect it from moisture or water.
Motor Protection Devices:
Winding Temperature Sensors: Provide a minimum of two thermistor
temperature detectors embedded in the end coils of the stator, spaced directly
across from each other. Thermal sensors shall automatically de-energize the
motor when its temperature exceeds apreset limit recommended by the
manufacturer.
Provide moisture sensor to sense seal failure; mounted in the seal chamber; of
the conductive type; sensing moisture above the lower seal.
Provide moisture sensing to detect liquid intrusion in the power cable
termination chamber and into the motor space.
Provide motor protection relay and required power supply to the CONTRACTOR
for mounting the VFD.
2.6ACCESSORIES
Anchor Bolts: Provide template and Type 316 stainless steel anchors and fasteners in
accordance with Section 05 05 23 “Metal Fastenings and Anchor Bolts”, as shown on the
Drawings, and as recommended by the EQUIPMENT SUPPLIER. Size and locations as
required by EQUIPMENT SUPPLIER. EQUIPMENT SUPPLIER shall size all anchor bolts and
fasteners required of ample size and strength for the intended purpose, minimum of ½-inch
diameter. Fastener sizing calculations shall be provided as an informational submittal.
CONTRACTOR shall furnish and install all anchor bolts and fasteners in accordance with the
equipment supplier’s installation instructions.
Equipment Identification Plates: EQUIPMENT SUPPLIER shall furnish a 16-gauge Type 316
stainless steel identification plate securely mounted on the equipment in a readily visible
location. The plate shall bear 1/4-inch die-stamped equipment identification number
indicated in this Section and/or on the Drawings.
Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 60
pounds shall be provided with lifting lugs.
Initial Supply of Lubricants: EQUIPMENT SUPPLIER shall indicate types, brands, and
quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants and shall comply with all
equipment supplier recommended procedures.
2.7SPARE PARTS
Furnish extra materials that match products installed and that are packaged with protective
covering for storage and identified with labels describing contents.
One (1) set of the following spare parts shall be furnished for each size of pump
provided under this specification:
Mechanical seals.
Suction cover insert ring, or alternatively, wear plate.
Bearingsfor each size and type.
Special tools required for maintenance or adjustment.
Other parts as recommended by manufacturer as typically needed in the first two
years of operation.
2.8PERFORMANCE REQUIREMENTS
Guaranteed Performance: Transfer the product at the operating conditions as listed in the
Pump Data Sheet.
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0537-038-01PUMP, DRY PIT SUBMERSIBLE -CENTRIFUGAL JANUARY 2023
Pumping Unit System: Comply with performance requirements specified, as determined by
testingassemblies representing those indicated for this Project.
Specific Performance Requirements: Refer to attached Pump Data Sheet after End of
Section.
EXECUTION
3.1INSTALLER
General:
Contractor shall install and adjust equipment in accordance with the Drawings,
approved shop drawings, and the EQUIPMENT SUPPLIER's instructions. Equipment
shall not be operated until the installation is approved by the EQUIPMENT SUPPLIER’s
representative.
Comply with the requirements of Section 01 75 25 “Equipment Testing and Startup”.
3.2EXAMINATION
Verify structures, pipes, and equipment are compatible.
3.3PREPARATION –NOT USED
3.4INSTALLATION
Support all piping independently of the pump.
Adjust pump assemblies such that the pump assembly is properly aligned, plumb, and level.
Do not compensate for misalignment by use of flexible couplings.
After the pump assembly has been set in positionon the existing concrete padand aligned
with the existing piping, grout the space between the bottom of the pump and the top of
the concrete pad with non-shrink grout. Existing concrete pad shall be modified as needed
to align the pump with the existing suction and discharge piping.
Complete equipment installation with controls, safety devices and auxiliary support systems
necessary to start the equipment and verify that the equipment functions correctly under no
load conditions. Turn rotating equipment by hand to check. Complete cleaning and testing
of piping systems. Inspect and clean equipment, devices, piping, and structures of debris
and foreign material.
Remove temporary bracing supports and other construction debris that may damage
equipment.
Remove protective coatings and oils used for protection during shipment and installation.
Flush, fill, and grease lubricated systems in accordance with manufacturer's instructions.
Install temporary connections and devices required to fill, operate, checkout and drain the
system. Provide temporary valves, gauges, piping, test equipment, and other materials and
equipment necessary to conduct testing and startup.
Equipment
Check equipment for correct direction of rotation and freedom of moving parts.
Align equipment to Manufacturer's tolerances. Adjust clearances and torques.
Check installation prior to start-up for conformance to manufacturer's instructions.
Adjust or modify equipment to ensure proper operation.
Correct any deficiencies or problems noted in manufacturer's representative's installation
reports.
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3.5FIELD QUALITY CONTROL
Functional Tests: Conduct on each pump as described below and in accordance with Section
01 75 25 “Equipment Testing and Startup.”
Alignment: Test complete assemblies for correct rotation, proper alignment and
connection, and quiet operation.
Vibration Test:
Test units installed and in normal operation, discharging to the connected
piping systems at rates between the low discharge head and high discharge
head conditions specified, and with the actual facility structures and
foundations provided. At any frequency or in any plane, peak-to-peak vibration
amplitudes shall not occur that exceed the limits specified.
If units exhibit vibration in excess of the limits specified adjust or modify as
necessary. Units which cannot be adjusted or modified to conform as specified
shall be replaced.
Flow Output: Measured by plant instrumentation and storage volumes.
Performance Test: In accordance with Hydraulic Institute Standards.
Place each piece of equipment in the system in operation until the entire system is
functioning. All components shall continue to operate without alarms or shut downs,
except as intended, for eight consecutive hours to be considered started up.
Operate the equipment through the design performance range consistent with
available flows. Adjust, balance, calibrate, and verify that the equipment, safety
devices, controls, and process system operate within the design conditions. Each
safety device shall be tested for proper setting and signal. Response shall be checked
for each equipment item and alarm. Simulation signals may be used to check
equipment and alarm responses.
A copy of all information from functional tests, including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
3.6SYSTEM STARTUP
Startup of the facility shall be in accordance with Section 01 75 25 “Equipment Testing and
Startup.”After initial startup under the supervision of a qualified representative of the pump
manufacturer, a preliminary “running-in” period will be provided for the CONTRACTOR, per
the Contract Documents, to make field tests and necessary adjustments. At the end of the
specified period of operation, the pumps will be accepted if, in the opinion of the ENGINEER,
the pumps haveoperated satisfactorily without excessive power input, wear, lubrication, or
undue attention required for this operation, and if all rotating parts operate without
excessive vibration or noise at any operating speed and head, including shutoff.
3.7MANUFACTURER’S SERVICES
Manufacturer’s Representative: Present at Project site or classroom designated by OWNER,
for minimum person-days listed below, travel time excluded:
No. Person DaysWork Description
1 Installation assistance and inspection.
1 Functional and performance testing.
1/4 Pre-startup classroom or site training.
1/2 Facility startup.
1/4 Post-startup training of OWNER’S personnel.
Services Provided:
PLUMMER ASSOCIATES, INC.43 21 39 - PAGE 10OF 12BID SET
0537-038-01PUMP, DRY PIT SUBMERSIBLE - CENTRIFUGAL JANUARY 2023
Furnish test forms and procedures for field-testing.
Furnish startup services.
Furnish training of OWNER’S personnel at such times requested by OWNER.
Manufacturer’s services and training shall comply with the requirements of Section 01 75 25,
“Equipment Testing and Startup.”
3.8CLOSEOUT ACTIVITIES –NOT USED
3.9SUPPLEMENT
The Pump Data Sheets included after “END OF SECTION” shall be part of this Section.
END OF SECTION
PLUMMER ASSOCIATES, INC.43 21 39 -PAGE 11OF 12BIDSET
0537-038-01PUMP, DRY PIT SUBMERSIBLE -CENTRIFUGAL JANUARY 2023
TABLE 1: RAS PUMPS
BRD-RAS-PMP11, -PMP12
Equipment Tag Number(s)
-PMP21, -PMP22
4 (1 duty, 1 standby for each
Quantity
clarifier)
Service Conditions
Liquid Pumped Mixed Liquor
o
Liquid Temperature, F Max: 86 Min: 50
Largest Diameter Solid Pump shall be
2.3
Capable of Passing, inches
Abrasive (Y/N) Y
Possible Scale Buildup (Y/N) N
Explosion-proof (Y/N) Y
Continuous Duty (Y/N) Y
Performance Requirements
Design Flow Rate, gpm 1,400
High Total Head at Design Flow Rate, FT 29.24
Low Total Head at Design Flow Rate, FT 13.22
Pump Efficiency, % 65
Maximum Net Positive Suction Head
28.75
Required at Required Design Flow, FT
Maximum Shutoff Head at Full Speed, FT 32.2
Pump Speed, Maximum, rpm 1,755
Pump Construction Details
Suction (Size) 8”, 125# Flange
Discharge (Size) 8”, 125# Flange
Hydrostatic Test Pressure (psig) 1.5 Times Shutoff Head
Field Testing (Required/Not Required) Required
Impeller Diameter (in), minimum 8.15
Vent and drain connections tapped and
Y
plugged
Shaft sealing Mechanical Seals
Motor Information
HP, Maximum 20
Speed, RPM 1,755 Max.
Starts per hour, evenly spaced 10
Power 480V/3PH/60Hz
Constant Speed (Y/N) N
Adjustable Speed (Y/N) Y
Inverter Duty Rated, Minimum Turndown
Yes, 50%
%
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0537-038-01 PUMP, DRY PIT SUBMERSIBLE - CENTRIFUGAL JANUARY 2023
F:\\PROJECTS\\0537\\038-01\\9 DESIGN\\9-4 SPECIFICATIONS\\CONFORMED\\43 21 39 PUMP, DRY PIT SUBMERSIBLE - CENTRIFUGAL.DOCX
SECTION 43 22 10
COMMON REQUIREMENTS FOR PUMPS
GENERAL
1.1RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division1 Specification Sections, apply to this Section.
1.2SUMMARY
Scope of Work:
This Section provides requirements common to the pumping unit specification
sections of Division 43 and 46. In addition to the specific requirements of the
individual pumping unit specification sections. The EQUIPMENT SUPPLIER and
CONTRACTOR shall be responsible for ensuring all pumping units comply with the
requirements of this Section. The detailed equipment specifications shall govern
where this section conflicts with detailed sections.
CONTRACTOR shall furnish and install all tools, equipment, materials, and supplies
and shall perform all labor necessary for the installation, testing, and placing into
operation of all pumps and pumping appurtenances, complete and operable, in
accordance with the requirements of the Contact Documents.
Related Sections:
Section 26 20 00.01 “NEMA Frame Induction Motors, 600 Volts and Below”.
Section 40 05 91 “Common Control Panel Requirements” for control panel
components and enclosure for vendor furnished control panels for equipment.
Section 40 05 05 “Piping Systems, Basic Materials and Methods” for basic piping
requirements associated with equipment systems, along with the individual piping
sections.
Section 40 05 51 “Common Requirements for Process Valves” for basic valve
requirements associated with equipment systems, along with the individual valve
sections.
1.3REFERENCES
Reference Specifications, Standards, Codes, and Regulations:
Various Project sections contain references to specifications, standards, codes,
regulations, and other documentation and shall be considered a part of those sections
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 the Project specification sections
and those of the listed documents, the requirements of the Project specification
sections shall prevail.
Unless otherwise specified, references to documents shall mean the documents in
effect at the time of Opening of Bid. 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
areno replacement documents, the last version of the document before it was
discontinued.
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Commercial Standards: All equipment, products, and their installation shall be in accordance
with the following standards, as applicable, and as specified in each Section of these
specifications.
American Society for Testing and Materials (ASTM).
American Public Health Association (APHA).
American National Standards Institute (ANSI).
American Society of Mechanical Engineers (ASME).
American Water Works Association (AWWA).
American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE).
American Welding Society (AWS).
Federal Specifications (FS).
Rubber Manufacturers of America (RMA).
Manufacturer's published recommendations and specifications.
GeneralIndustry Safety Orders (OSHA).
The following standards are referred to in the various Project specification sections:
American National standards Institute (ANSI):
B16.1 Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800.
B16.5 Pipe Flanges and Flanged Fittings, Steel, Nickel Alloy, and Other Special
Alloys.
American Society of Mechanical Engineers (ASME):
B31.3 Process Piping Code.
B73.1 Specifications for Horizontal End Suction Centrifugal Pumps for Chemical
Process.
B73.2 Specifications for Vertical In-Line Centrifugal Pumps for Chemical
Process.
American Water Works Association (AWWA):
E101 Deep Well Vertical Turbine Pumps-Line Shaft and Submersible Types.
ASTM International, Inc. (ASTM):
A 48 Specification for Gray Iron Castings
A108 –Specification for Steel Bar, Carbon and Alloy, Cold-Finished
A 470 Specification for Vacuum-Treated Carbon and Alloy Forgings for Turbine
Rotors and Shafts.
A519 –Standard Specification for Seamless Carbon and Alloy Steel Mechanical
Tubing
A532 –Specification for Abrasion-Resistance Cast Irons
A 536 Specification for Ductile Iron Castings.
A582 –Specification for Free-Machining Stainless Steel Bars
E 448 Recommended Practice for Scleroscope Hardness Testing of Metallic
Materials.
B 62 Specification for Composition Bronze or Ounce Metal
Castings.
Hydraulic Institute Standards for Centrifugal, Rotary, and Reciprocating Pumps.
National Electrical Manufacturer’s Association (NEMA): MG-1, Motors and Generators.
National Fire Protection Association (NFPA): NFPA 70, National Electric Code.
National Sanitation Foundation (NSF): NSF 61, Drinking Water Components –Health
Effects.
1.4SUBMITTALS
The information requested in the various Project specification sections shall be prepared in
accordance with the requirements described in the following paragraphs.
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Equipment and Related Lists: Lists are included for the convenience of the ENGINEER and
CONTRACTOR and are not complete listings of all pumps, equipment, devices and material
to be provided under this Contract. The CONTRACTOR agrees to prepare his own material
and equipment takeoff lists as necessary to meet the requirements of the Project.
Manufacturer Installation Instructions: Instructions for field procedures for erection,
adjustments, inspection, and testing shall be provided prior to installation of the pumping
units.
Pump Submittal Requirements: Following are supplemental requirements for pumping unit
submittals.
Manufacturer to indicate points on the head/capacity curves, and the limits
recommended for stable operation which the pumps may be operated without surge,
cavitation and vibration. The stable operating range shall be as wide as possible
based on the pumps actual hydraulic and mechanical tests.
Pump detailed description and specification.
Assembly and installation drawings including shaft size, seal, coupling, anchor bolt
plan, part nomenclature, material list, outline dimensions and shipping weights.
Bearing life calculations.
Documentation demonstrating factory finish is equivalent to finish system specified in
this Section.
Motors:
Complete submittal per Section 26 20 00.01 “NEMA Frame Induction Motors, 600
Volts and Below.”
Electrical:
Auxiliary Instrumentation and Devices: Datasheets and mounting locations/details for
auxiliary instrumentation and devices furnished with equipment. The information
shall include associated mounting brackets and hardware.
Wiring Diagrams: If applicable, for power, signal, and control wiring diagrams,
including terminals and numbers.
Complete submittal per Section 26 29 23.11 “Low Voltage Variable Frequency Drives”.
Information Submittals:
Manufacturer’s Certification of Compliance.
Special shipping, storage and protection, and handling instructions.
Manufacturer’s Instructions for installation.
Manufacturer’s Certificate of Proper Installation.
Qualification Data: For manufacturer and manufacturer’s representative.
Suggested spare parts list to maintain the equipment in service for a period of two
years. Include a list of special tools required for checking, testing, parts replacement,
and maintenance with current pricing information.
List special tools, materials, and supplies furnished with equipment for use prior to
and during startup and for future maintenance.
Warranties and service agreements.
Operation and Maintenance Data: For each pumping system to include in operationand
maintenance manuals in accordance with Section 01 78 23“Operation and Maintenance
Data.”
Guarantees and Warranties: After completion, the CONTRACTOR shall furnish to the OWNER
the manufacturer's written guarantees, that the pumping units will operate within the
published efficiencies, heads, and flow ranges and meet these specifications.
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1.5QUALITY ASSURANCE
Performance Curves: All centrifugal pumps shall have a continuously rising curve. In no case
shall the required horsepower at any point on the performance curve exceed the rated
horsepower or service factor of the motor or engine.
Manufacturer Qualifications: Unless otherwise specified in the individual specification
sections:
All equipment shall be the product of a manufacturer which has been in the design,
fabrication, assembly, testing, start-up and service of full scale pumping units with at
least fifteen (15) North American installations of the type, model,and size specified
for a period of not less than five (5)years prior to the bid date of this Contract. All
equipment of each type specified in this section shall be supplied by a single
EQUIPMENT SUPPLIER who is fully experienced, reputable and qualified in the
manufacture of the equipment to be furnished. The equipment shall be designed,
constructed, and installed in accordance with the best practices and methods.
A list of similar installations shall be furnished with the shop drawing submittal,
including names and telephone numbers of contacts.
Installer Qualifications:
Unless otherwise specified in the individual specification sections; CONTRACTOR shall
provide a manufacturer's authorized representative who is trained and approved for
installation of units required for this Project.
Manufacturer’s representative shall be provide for each pumping unit, 2 HP and larger
for the periods indicated in the individual specification section.
Source Limitations: Pumping units of each type specified as specified in the individual
specification sections shall be supplied by a single manufacturer. This does not require that
all equipment be manufactured by a single manufacturer, but does require that the
manufacturer of the system shall be responsible for the complete system.
All equipment shall have a 316 stainless steel manufacturer’s nameplate securely affixed in a
conspicuous place on the equipment showing the ratings, serial number, model number,
manufacturer and other pertinent nameplate data.
Manufacturer shall maintain a complete stock of spare parts commonly needed for the
equipment specified at a location within the State of Texas, or spare parts shall be made
available within 48hours ofnotification.
Electrical Components, Devices, and Accessories: UL Listed and labeled as defined in
NFPA70, and marked for intended location and application.
Previous Installations List: A list of similar installations demonstrating the experience
requirement shall be furnished. List shall include EQUIPMENT SUPPLIER name. Each
installation shall include project State, project City, project name, project date, equipment
model number, owner (end user) name(s), and owner phone number(s).
1.6DELIVERY, STORAGE,AND HANDLING
Deliver, handle and store equipment components in accordance with shop drawings,
manufacturer’s written instructions, and the requirements of Section 01 60 00 “Product
Requirements”. Special requirements for the storage and handling of pumping units will be
provided in the specified pumping unit section.
Motors shall be stored as indicated in Section 26 20 00.01 “NEMA Frame Induction Motors,
600 Volts and Below.”
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1.7PROJECT CONDITIONS
Structural Performance: All equipment, supports, anchors andfasteners shall be of
adequate size and strength to withstand loads associated with starting, turbulence, debris,
thrusts from liquid movement, thermal expansion and contraction and other loads
encountered under operating conditions.
Operation: Equipment shall be designed and capable of either continuous or intermittent
operation.
System Arrangement:
The equipment, sizes, materials, and arrangements described in the individual
specification sections are typically based on recommendations by equipment
manufacturers and shall be considered minimum limits of acceptability. The
equipment MANUFACTURER shall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
Environmental Conditions:
All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide andother
corrosive gases encountered in municipal wastewater treatment plants.
All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 110°F.
Equipment shall be compatible with heat tracing and insulation, which will be
furnished and installed by the CONTRACTOR. EQUIPMENT SUPPLIER shall design
piping systems with ample clearances and material compatibility to accept required
heat tracing and insulation. If additional freeze protection beyond heat tracing and
insulation is required it shall be furnished by the EQUIPMENT SUPPLIER. EQUIPMENT
SUPPLIER shall coordinate with the CONTRACTOR to provide direction on where heat
tracing is required, and shall verify that the CONTRACTOR has provided adequate
heat tracing and insulation during startup activities.
Field Measurements, Existing Facilities Installation: CONTRACTOR shall verify actual
dimensions of openings, adjacent facilities and equipment, utilities and related items by field
measurements before fabrication asapplicable.
1.8WARRANTY
Extended Equipment Warranty: Refer to Section 01 78 36 “Warranties” for extended
equipment warranty.
All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for aperiod of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
1.9SPARE PARTS AND TOOLS
Tools: Provide special tools necessary for maintenance and repair of the pumps shall be
furnished as a part of the work hereunder; such tools shall be suitably stored in metal tool
boxes, and identified with the equipment number by means of stainless steel or solid plastic
name tags attached to the box.
Spare Parts:
Obtain and submit from the manufacturer a list of recommended spare parts for each
piece of equipment. After approval, furnish such spare parts suitably packaged,
identified with the equipment number, and labeled.
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Furnishthe name, address, and telephone number of the nearest distributor for each
piece of equipment. All spare parts are intended for use by the OWNER, only, after
expiration of the warranty period.
Any spare parts which the CONTRACTOR was permitted to use for startup activities
shall be replaced by the CONTRACTOR prior to the OWNER's acceptance of beneficial
use of the equipment.
During the term of this Contract the CONTRACTOR shall notify the ENGINEER in
writing about any manufacturer's modification of theapproved spare parts, such as
part number, interchangeability, model change or others. If the ENGINEER
determines that the modified parts are no longer applicable to the supplied
equipment, the CONTRACTOR at its expense shall provide applicable spare parts.
PRODUCTS
2.1GENERAL REQUIREMENTS
The CONTRACTOR shall furnish and install only such equipment as the designated single
manufacturer certifies is suitable for use with its equipment and the service conditions.
All manufactured items provided under this Section shall be new, of current manufacture,
and shall be the products of reputable manufacturers specializing in the manufacture of such
products; such manufacturers shall have had previous experience in such manufacture and
shall, upon request of the ENGINEER, furnish the names of not less than five (5) successful
installations of its equipment of comparable nature to that offered under this Contract.
All combinations of manufactured equipment which are provided under these specifications
shall be entirely compatible, and the CONTRACTOR and the designated single manufacturer
shall be responsible for the compatible and successful operation of the various components
of the units conforming to specified requirements. Each unit of equipment shall incorporate
all basic mechanisms, coupling, electric motor or engine drive and unit mounting. All
necessary mountings and appurtenances shall be included.
Where two or more units of the same type and/or size of equipment are required, such units
shall all be produced by the same manufacturer.
Tolerance: Tolerances and clearances shall be as shown on the shop drawings and shall be
closely adhered to. Machine work shall in all cases be of high-grade workmanship and finish,
with due consideration to the special nature or function of the parts.
Machine Finish: The type of finish shall be the most suitable for the application and shall be
shown in micro-inches in accordance with ANSI B46.1. The following minimum finishes shall
be used:
Surface roughness not greater than 63 micro-inches shall be required for all surfaces
in sliding contact.
Surface roughness not greater than 250 micro-inches shall be required for surfaces in
contact where a tight joint is not required.
Rough finish not greater than 500 micro-inches shall be required for other machined
surfaces.
Contact surfaces of shafts and stems which pass through stuffing boxes and contact
surfaces of bearings shall be finished to not greater than 32 micro-inches.
Noise Level:
When the equipment is in operation, no single piece of equipment shall exceed the
OSHA noise level requirements for a one-hourexposure, and the regulatory agency
having jurisdiction where the Project is located.
The maximum allowable noise level shall correspond to the type of occupancy and
area classification as specified and shown on the Drawings.
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For additional products requirements, refer to Section 01 60 00 “Product Requirements” for
administrative and procedural requirements for selection of products for use in the Project;
product delivery, storage, and handling; manufacturers' standard warranties on products;
special warranties; product substitutions; and comparable products.
2.2PUMPING UNIT REQUIREMENTS
Materials: All materials furnished as part of the pumping equipment shall be suitable for its
intended use and service. Materials not specifically called for shall be high-grade, standard
commercial quality, free from all defects and imperfection that might affect the serviceability
of the product for the purpose for which it is intended, and, unless otherwise specified in the
individual specification section, shall conform to the following requirements:
Cast iron pump casings and bowls shall be of close-grained gray cast iron, conforming
to ASTM A48, or equal.
Bronze pump impellers shall conform to ASTM B 62.
Stainless steel pump shafts shall be of Type 400, Series. Miscellaneous stainless steel
parts shall be of Type 316.
All anchor bolts, nuts and washers shall be Type 316 stainless steel, unless otherwise
specified.
Buried or submerged bolts, nuts and washers shall be Type 316 stainless steel.
Bearings: Unless otherwise specified, bearings shall comply with the requirements listed
below.
Be oil or grease lubricated, ball or roller type, designed to withstand the stresses of
the service specified.
Rated in accordance with the latest revisions of ABMA Methods of Evaluating Load
Ratings of Ball and Roller Bearings.
Have a minimum L-10 rating life of 50,000 hours. The rating life shall be determined
using the maximum equipment operating speed.
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.
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°C and equipped with a filler pipe and an
external level indicator gauge.
Couplings:
General: Pumps 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.
Requirements:
Accommodate angular misalignment, parallel misalignment and end float, and
cushions shock loads and dampens torsion vibrations.
Consist of a tire with synthetic tension members bonded together in rubber;
flexible member attached to flanges by means of clamping rings and cap
screws; andflanges attached to the stub shaft by means of taperlock bushings
which provide 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.
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Where torque or horsepower capacities of couplings of the foregoing type is
exceeded, provide Thomas-Rex, Falk Steel Flex, or equal couplings will be
acceptable.
V-Belt Drives:
V-belts and sheaves shall be of the best commercial grade and shall conform to ANSI
and RMA Standards.
Unless otherwise specified, sheaves shall be machined from the finest quality gray
cast iron.
Sheaves shall be statically balanced. For high-speedapplication, where vibration is a
problem, sheaves shall be dynamically balanced. Sheaves operating at high belt
speeds may be required to be constructed of special materials.
To facilitate installation and disassembly, sheaves shall be furnished complete with
taper lock or QD bushings as required.
Finish bored sheaves shall be furnished complete with keyseat and set screws.
Sliding motor bases shall be provided to adjust the tension of V-belts.
Flanges: Suction and discharge flanges shall conform to ANSI standard B16.1 or B16.5
dimensions.
Lubrication:
Vertical pump shafts shall be product water-lubricated, unless otherwise specified.
Deep-well pumps and pumps with dry barrels shall have water-or oil-lubricated
bearings and seals.
For all vertical propeller, mixed-flow, and turbine pumps, other than deep well pumps,
of bowl sizes 10-inch and larger, the CONTRACTOR shall provide a Type 316 stainless
steel tube attached to the column for grease lubrication of bottom bearing.
Handholes: Handholes on pump casings shall be shaped to follow the contours of the casing
to avoid any obstructions in the water passage.
Vortex Suppressors: Vertical pumps with insufficient submergence shall be furnished with
vortex suppressors.
Drains: All gland seals, air valves, and cooling water drains shall be piped to the nearest
floor sink, or drain, with galvanized steel pipe or copper tube, properly supported with
brackets.
Seals: Seals for water and wastewater pump shafts shall be either stuffing box or
mechanical seals. Unless specified otherwise, stuffing boxes and mechanical seals shall be
selected for highest reliability and for rugged service, conforming to the requirements set
forth in this paragraph.
Stuffing Boxes: Where stuffing boxes are specified for the pump seal, they shall be of
the best quality, using the manufacturer's suggested materials best suited for the
specific application.
For sewage, sludge, drainage, and liquids containing sediments, the seals shall
be fresh-water flushed, using lantern rings.
Description: Stuffing boxes shall be tapped to permit introduction of seal liquid
and shall hold a minimum of five rows of packing.
Stuffing boxes shall be face attached.
Stuffing box and shaft shall be suitable for field installation, without machining
or other modifications, of the mechanical seal specified above for the applicable
pump and operating conditions.
Lantern Rings: Bronze or Teflon, two-piece construction, and provided with
tapped holes to facilitate removal.
Packing: Unless otherwise specified, the packing material shall be die-molded
packing rings of interlaced Teflon braiding, containing 50 percent ultrafine
graphite impregnation to satisfy the following specification:
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Shaft speeds -up to 2500 fpm
Temperature -up to 500 degrees F
pH range -0-14
Glands: Bronze, two piece split construction.
Impeller end of the packing on all but line-shaft pumps with external source
water lubricated bearings shall be fitted with a SpiralTrac, Version P packing
protection system as manufactured by EnviroSeal Engineering Products, Ltd,
Nova Scotia, Canada.
Mechanical Seals:
Description: Mechanical seal 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.
Mechanical seals shall be the split cartridge type, requiring no field assembly,
other than assembly around the shaft and insertion into the pump. Metal parts
shall be Type 316 or 316L stainless steel. Springs shall be Hastalloy C.
Rotary Faces: Ceramic or silicon carbide.
Stationary Faces: Ceramic, tungsten carbide, or silicon carbide.
Elastomers: Ethylene propylene or fluorocarbon.
Service Operation: Full vacuum to 200 percent of the maximum specified
operating pressure, but in any event not less than 200 psig.
Unless otherwise specified, mechanical seals for pumping equipment shall be
self-aligning, self-centering, single, Chesterton 442, AES or equivalent.
Mechanical seals for all pumps (except lineshaft pumps where the seal barrier
fluid is used for lineshaft bearing lubrication) shall be fitted with SpiralTrac
Version F, N or D, as recommended by EnviroSeal Engineering Products, Ltd,
Nova Scotia, Canada.
Unless the pump manufacturer recommends a better seal for a specific
application, the following mechanical seals shall be furnished with the pumps:
Sewage, Sludge, or Double seals:
Wastewater Pumps:
Abrasives, Grit, Double seals:
Lime Slurry Pumps:
Chemicals, and Single seals:
Corrosive Liquid Pumps:
Clean Water Pumps, Single seals:
Hot and Cold:
For all seal arrangements, a buffer fluid must be circulated a minimum 20 psi
above suction pressure, or as required by manufacturer, in order to maintain
reliable seal performance.
Shaft Sleeve:
Section of shaft or impeller hub extending through or into the stuffing box shall
be fitted with a replaceable stainless steel sleeve, having a Brinell hardness of
not less than 500.
Sleeve held to the shaft to prevent rotation and gasketed to prevent leakage
between the shaft and the sleeve.
Minimum shaft sleeve thickness shall be 3/8 inch.
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2.3PUMP APPURTENANCES
Manufacturer Nameplate: Each pump shall be equipped with a Type 316 stainless steel
nameplate indicating rated head and flow, impeller size, pump speed, manufacturer's name
and model number, and other appurtenant information.
Equipment Identification Plates: A 16-gauge Type 316 stainless steel identification plate
shall be securely mounted on the equipment in a readily visible location. The plate shallbear
1/4-inch die-stamped equipment identification number indicated in this Section and/or on
the Drawings.
Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 80
pounds shall be provided with lifting lugs
Anchor Bolts: Provide template and Type 316 stainless steel anchors in accordance with
Section050523 “Metal Fastenings and Anchor Bolts” and as shown on the Drawings. Size
as required by manufacturer.
Initial Supply of Lubricants: Manufacturer shall indicate types, brands, and quantities of
initial lubricants, oil, grease, etc. necessary to startup equipment. CONTRACTOR shall
provide and install the recommended lubricants and shall comply with all manufacturer
recommended procedures.
Solenoid Valves: The pump manufacturer shall furnish and install solenoid valves on the
water or oil lubrication lines and on all cooling water lines. Solenoid valve electrical rating
shall be compatible with the motor control voltage and shall be furnished complete with all
necessary conduit and wiring installation from motor control panel to solenoid. Solenoid
valve voltage shall be 120VAC, unless noted otherwise.
Pressure Gauges: Gaugetaps shall be provided on the suction and discharge sides of pumps
(except sample pumps, sump pumps, and hot water circulating pumps) and shall be
equipped with pressure gauges installed at pump suction and discharge lines. Pressure
gauges, when shown, shall be provided by the CONTRACTOR, unless specifically stated
otherwise in the pump specification.
Pressure gauges shall be located in a representative location, where not subject to
shock or vibrations, in order to achieve true and accurate readings.
Pressure gauges shall be furnished in conformance with Section 40 73 99, “Piping
System, Pressure Gauges, andThermometers”.
Pump suctions shall be equipped with compound gauges. Where subject to shock or
vibrations, provide a snubber, which is wall-mounted or attached to galvanized
channel floor stands and connected by means of flexible connectors.
Guards: Exposed moving parts shall be provided with guards which meet the requirements
of OSHA. Guards shall be fabricated of minimum 14-gaugeType 316 stainless steelor
fiberglass; designed to be readily removable to facilitate maintenance of moving parts.
Safety Signs: Provide the following safety signs in accordance with:
Equipment with guarded moving parts which operates automatically or by remote
control shall be identified signs reading "CAUTION -EQUIPMENT STARTS AND STOPS
AUTOMATICALLY.”
Place a caution sign on the guard reading “CAUTION-KEEP GUARD IN PLACE.”
2.4SOURCE QUALITY CONTROL
CONTRACTOR shall be responsible for the coordination of the following tests of each of each
pump, motor controller, and motor:
General: Tests shall be performed in accordance with the Test Code for Centrifugal Pumps
of the Standards of the Hydraulic Institute, Inc. Tests shall be performed on the actual
assembled unit from shut-off head condition to 150 percent of the required maximum design
capacity. Prototype model tests will not be acceptable.
Factory Tests of Pumps:
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All pumps and motors of sizes 10 to 125 hp (inclusive) shall be factory-tested in
accordance with the above specifications. Submit the Certified test data to the
ENGINEER. This data shall include, but not belimited to the following:
Hydrostatic test with data recorded.
Hydraulic test with a minimum of 5 readings between shutoff head and 125
percent of the maximum design capacity, recorded on data sheets as defined
by the Hydraulic Institute, signed, dated, and certified.
Certification that the pump HP demand will not exceed the rated motor hp
beyond the 1.0 service rating at any point on the curve.
Vibration Test: Dynamically balance rotating parts of each pump and its driving unit
before final assembly. Limits; Complete rotating assembly, including drive unit and
motor, shall be less than 90 percent of limits established in the Hydraulic Institute
Standards.
Factory Tests of Motors: Motors shall be factory tested as indicated in Section 26 20 00.01
“NEMA Frame Induction Motors, 600 Volts and Below.”
Factory Witnessed Tests: All pumps, and motors, 150 hp and larger, shall be factory-tested
as complete, assembled units, as specified above, and witnessed by the ENGINEER and the
OWNER.
Manufacturer shall provide the ENGINEER a minimum of two (2) weeks notification
prior to the test.
All costs for OWNER and ENGINEER shall be borne by the CONTRACTOR and included
in the bid price. Such costs shall include travel and subsistence for two people but
shall exclude any salaries. Provide copies of the test results to the ENGINEER and no
equipment shall be shipped until the test data have been approved.
Acceptance: In the event of failure of any pump to meet any of the individual section
requirements or efficiencies, the CONTRACTOR shall make all necessary modifications,
repairs, or replacements to conform to the requirements of the Contract Documents and the
pump shall be re-tested at no additional compensation, until found satisfactory.
EXECUTION
3.1GENERAL
Install and adjust equipment in accordance with the Drawings, approved shop drawings, and
the manufacturer's instructions. Do not operate the equipment until the installation is
approved by the manufacturer’s representative.
3.2INSTALLATION
Assemble and install equipment in accordance with the manufacturer's instructions and the
following:
Support all piping independently of the pump.
Level baseplate by means of steel wedges (steel plates and steel shims). Wedge taper
not greater the 1/4-inch per foot. Use double wedges to provide a level bearing
surface. Accomplish wedging so that there is no change of level or springing of the
base elbow when anchor bolts are tightened.
Adjust pumpassemblies such that the driving units are properly aligned, plumb, and
level with the driven units and all interconnecting shafts and couplings. Do not
compensate for misalignment by use of flexible couplings.
After the pump and driver have been set in position, aligned, and shimmed to the
proper elevation, grout the space between the bottom of the baseplate and the
concrete foundation with a poured, non-shrinking grout of the proper category, as
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specified in 0 “Grout, Non-Shrink.” Remove wedges after grout is set and pack void
with grout.
Complete equipment installation with controls, safety devices and auxiliary support
systems necessary to start the equipment and verify that the equipment functions
correctly under no load conditions. Turn rotating equipment by hand to check.
Complete cleaning and testing of piping systems. Inspect and clean equipment,
devices, piping, and structures of debris and foreign material.
Remove temporary bracing supports and other construction debris that may damage
equipment.
Remove protective coatings and oils used for protection during shipment and
installation.
Flush, fill, and grease lubricated systems in accordance with manufacturer's
instructions.
Seal Water Connections: Provide seal water ping, valves, flow indicator, pressure and flow
control devices, to pump packing for units handling slurries, grit, water containing sand or
solids, and as specified in the drawings in accordance with the Standard Details.
Base Plate Drains: Provide drain line from pumping unit base to the floor drain.
Install temporary connections and devices required to fill, operate, checkout and drain the
system. Provide temporary valves, gauges, piping, test equipment, and other materials and
equipment necessary to conduct testing and startup.
Equipment
Check equipment for correct direction of rotation and freedom of moving parts.
Align equipment to Manufacturer's tolerances. Adjust clearances and torques.
Check installation prior to start-up for conformance to manufacturer's instructions.
Adjust or modify equipment to ensure proper operation.
Correct any deficiencies or problems noted in manufacturer's representative's installation
reports.
3.3PROTECTIVE COATING
Provide polyurethane, pigmented (over epoxy zinc rich primer and high build epoxy) in
accordance with Section 09 91 00 “Painting and Protective Coatings.” Pump shall receive
surface preparation, prime coat and finish coat in factory.
Shop painted items which suffered damage to the shop coating shall be touched up as
specified in Section 09 91 00 “Painting and Protective Coatings.”
3.4FIELD QUALITY CONTROL
Functional Tests: Conduct on each pump as described below and in accordance with Section
01 75 25“Equipment Testing and Startup.”
Pumping units shall be field tested after installation, to demonstrate satisfactory
operation, without causing excessive noise, vibration, cavitation, and overheating of
the bearings.
Alignment: Test complete assemblies for correct rotation, proper alignment and
connection, and quiet operation.
Vibration Test:
Testunits installed and in normal operation, and discharging to the connected
piping systems at rates between the low discharge head and high discharge
head conditions specified, and with the actual facility structures and
foundations provided, shall not develop at any frequency or in any plane, peak-
to-peak vibration amplitudes exceeding the limits specified.
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Any vibration shall be within the amplitude limits recommended in the
Hydraulic Institute Standards and it shall be recorded at a minimum of four (4)
pumping conditions defined by the ENGINEER.
If units exhibit vibration in excess of the limits specified adjust, ormodify as
necessary. Units which cannot be adjusted or modified to conform as specified
shall be replaced.
Flow Output: Measured by plant instrumentation and storage volumes.
Performance Test: In accordance with Hydraulic Institute Standards.
Place each piece of equipment in the system in operation until the entire system is
functioning. All components shall continue to operate without alarms or shut downs,
except as intended, for eight consecutive hours to be considered started up.
Operate the equipment through the design performance range. Adjust, balance, and
calibrate and verify that the equipment, safety devices, controls, and process system
operate within the design conditions.
Each safety device shall be tested for proper setting and signal. Response shall be
checked for each equipment item and alarm. Simulation signals may be used to
check equipment and alarm responses.
Pump performance shall be documented by obtaining concurrent readings, showing
motor voltage, amperage, pump suction head, andpump discharge head, for at least
four (4) pumping conditions at each pump rpm. Each power lead to the motor shall
be checked for proper current balance.
Bearing temperatures shall be determined by a contact-type thermometer. A running
time of at least 20minutes shall be maintained for this test, unless liquid volume
available is insufficient for a complete test.
A copy of all information from functional tests, including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
3.5MANUFACTURER’S SERVICES
Manufacturers services shall comply with the requirements of Section 01 43 33
“Manufacturer’s Field Services” and training shall comply with the requirements of Section
01 79 00 “Demonstration and Training.”
Manufacturer’s representative shall be provided present at Project site or classroom
designated by OWNER, and depending of the Construction Schedule, provide the
number of trips required to provide the minimum person-days listed in the individual
specification sections, travel time excluded.
Inspection, Startup, and Field Adjustment: CONTRACTOR shall demonstrate that all
equipment meets the specified performance requirements. CONTRACTOR shall provide the
services of an experienced, competent, and authorized service representative of the
manufacturer of each item of major equipment and shall visit the site of work to perform the
following tasks.
Assist the CONTRACTOR in the installation of the equipment.
Inspect, check, adjust if necessary and approve the equipment installation.
Start-up and field-test the equipment for proper operation, efficiency, and capacity.
Perform necessary field adjustments during the test period until the equipment
installation and operation are satisfactory to the ENGINEER.
Instruct OWNER's personnel in the operation and maintenance of the equipment.
Instruction prior to system testing of the equipment shall include step-by-step
troubleshooting procedures with all necessary equipment testing.
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Manufacture’s Certificates:
Provideequipment manufacturer’s Certificate of Installation stating that the
equipment is installed per the manufacturer’s recommendations and in accordance
with the Drawings and Specifications.
Provide equipment manufacturer’s Certificate of Performance statingthat the
equipment meets or exceeds the performance requirements as defined hereinbefore.
3.6FACILITY STARTUP
Startup of the facility shall be in accordance with Section 01 75 25,“Equipment Testing and
Startup.” After initial startup under the supervision of a qualified representative of the pump
manufacturer, a preliminary “running-in” period will be provided for the CONTRACTOR, per
the Contract Documents, to make field tests and necessary adjustments. At the end of the
specified period of operation, the pumps will be accepted if, in the opinion of the ENGINEER,
the pumps has operated satisfactorily without excessive power input, wear, lubrication, or
undue attention required for this operation, and if all rotating parts operate without
excessive vibration or noise at any operating speed and head, including shutoff.
END OF SECTION
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SECTION 44 31 11
BIOLOGICAL TOWER-TYPE ODOR CONTROL SYSTEM
GENERAL
1.1SUMMARY
Section Includes:
The EQUIPMENT SUPPLIER shall furnish, install, startup, and test one (1)complete
Odor Control System (OCS), including two (2) foul air fans, one (1) biological tower-
type odor control units(bioscrubbersor biotrickling filter system), one (1) carbon
adsorber, appurtenances, instrumentation, and controls as specified herein and
referenced sections of the specifications and the Drawings. The components of the
OCS shall be furnished by a single supplier.
This section includesone(1)biological tower-type odor control system. The
biological tower-type odor control systemsshall include the tower unit, irrigation
system and mist eliminator(s), vessel(s)or container(s), inert inorganic media, valves,
pumps, inlet air plenum, conduit, wiring, and control system (compatible with the
Plant Control System (PCS)).
The systemshall be designed to treat odorous air from the Resaca Lift Station.
To ensure system compatibility, a single EQUIPMENT SUPPLIER is responsible for the
successful operation of each item of equipment and for the integrated system. The
responsibility of the EQUIPMENT SUPPLIER shallinclude the approval of installation,
system optimization, and warranties for the components and performance of the
complete Odor Control System.
1.2REFERENCES
Drawings and general provisions of the Contract, including Special Conditions and Division 1
Specification Sections, apply to this Section.
The following testing procedures shallbe used to verify performance of the equipment, most
current edition:
ASTM E679: Determination of Odor and Taste Threshold by a Forced-Choice
Ascending Concentration Series Method of Limits.
EN 13725: Air Quality –Determination of Odor Concentration by Dynamic
Olfactometry.
Related Sections:
Section 01 33 00,“Submittal Procedures”
Section 01 75 25,“Equipment Testing and Startup”
Section 09 91 00,“Painting and Protective Coatings”
Section 26 20 00.01,“NEMA Frame Induction Motors, 600 Volts and Below”
Section 40 05 36.13, “Foul Air Fiberglass Ductwork”
Section 40 05 51,“Common Requirements for Process Valves”
Section40 61 00, “Process Control and Instrumentation Systems -General Provisions”
Section40 63 00,“PLC Hardware and Software”
Section40 66 00, “Network Equipment”
Section 40 73 99,“Pressure Gauges and Thermometers”
Section 43 11 19,“Foul Air Fans”
Section 44 31 16,“Carbon Adsorber Odor Control System”
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1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Action Submittals
Product Data: Provide construction details, material descriptions, dimensions of
individual components and profiles, rated capacities, operating characteristics,
electrical characteristics, and furnished specialties and accessories.
Shop drawings specific to the project and applicable product data shallbe bound
neatly in a single package. The following information shallbe submitted, as a
minimum:
EQUIPMENT SUPPLIER shall provide a copy of this Section and indicate for
each specification item in this Section that the requirement is acknowledged. All
deviations from the contract documents shall be clearly identified in a separate
list.
Manufacturer and model number of equipment.
Safety Data Sheets.
Layout drawings including all proposed system components with dimensions,
clearances required and sizes indicated, anchor locations and sizes, details of
ductwork or piping connections, size and location of required electrical conduits
and conduit openings, and total weights of the product. Layout drawings shall
be to scale in English units, provided on 11”x17” bond paper and on compact
disk in AutoCAD format.
Include flow directions, process information, loading rates, empty bed
residence time(EBRT), water requirements, etc., descriptions and provisions
for adjustments and alarms on operating components. Indicate extent of shop
fabrication and field joint types and locations.
Detailed specifications and data describing the materials of construction,
material thickness, linings,and coatings for all components.
Submit data that verifies the system is capable of uniformly distributing flow
throughout the system without short-circuiting and will meet the specified
treatment requirements.
EQUIPMENT SUPPLIER shall provide a list of similar installations with reference
and contact information for operating systems. EQUIPMENTSUPPLIER shall
have a minimum of five (5) successful installations of similar size for
acceptance and shallhave at least five (5) similar systems in continuous
operation in similar applications for three (3) years. Submittals received without
current names and phone numbers for reference contacts may be deemed non-
responsive.
Descriptions and characteristics of media, anticipated media life at design
conditions and current replacement cost (material supply only) of media.
Nutrients required for startup and operation, including concentrations and
dosage rates, and range of operation.
Empty bed residence times for range of operating flows.
Headloss (inches of water column) through the bioscrubber media, distribution
plenum, and complete unit and odor control systemover range of flows.
All required utility connection points and supply requirements including power
and plant water(quality, quantity, and pressure).
Location and telephone number of nearest stocking distributor of spare parts.
Startup and test schedule with test procedures.
Equipment installation report with field test data and test records in accordance
with Section 01 33 00“Submittal Procedures”(submit as record data after
startup).
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Warranties and service agreements.
All structural design calculations, drawings, and associated items shall be
EQUIPMENT SUPPLIER’s responsibilities, and shall be including all scrubber
vessels items, deflection of the vessel at the point of connection with the
ductwork, thickness, anchor bolt size and location, hold-down lugs, lifting
hooks, and loads imposed by appurtenances such as inlet and outlet ducting
and internal media. The OWNER or OWNER’S Representative shallreview the
structural drawings and calculations for completeness only. All structural
drawings and calculations shall be signed and stamped by a Professional
Engineer (registered in the State of Texas) prior to submittal to the OWNER.
Design of system shallbe in accordance with applicable local, state, and
national standards and codes.
A certificate from the vessel manufacturer listing the nomenclature,
composition, and characteristics of the resin or other plastics shallbe supplied
with the submittal data, as well as vessel and support calculations as specified
if fiberglass is used for the scrubber vessel.
Calculations for irrigation requirements, including recirculation rates.
Any other information necessary for the OWNER or OWNER’S representative to
determine compliance with the specifications.
Motors:
Complete submittal per Section 26 20 00.01,“NEMA Frame Induction
Motors, 600 Volts and Below.”
Letter of Certification the motor is compatible with a variable frequency
drives when specified as adjustable speed operation.
Panels: Complete submittal per Section 40 05 91,“Common Control Panel
Requirements for Process Equipment.”
Auxiliary Instrumentation and Devices: Datasheets and mounting
locations/details for auxiliary instrumentation and devices furnished with
equipment. The informationshall include associated mounting brackets and
hardware.
Wiring Diagrams: If applicable, for power, signal, and control wiring diagrams,
including terminals and numbers.
Instrumentation and Control Submittals:
P&IDs and Process Flow Diagrams.
Instrument specifications in ISA Format with catalogue cut sheets.
Instrument list with tag names, ranges, alarm set points, and manufacturer
contact information.
Description of control system in written form including functions monitored,
controlled, and alarmed. Include sequence of operation and interface
requirements.
For all subsystems thatcommunicate with the Plant Control System, the system
supplier shall coordinate with the Plant Control System Integrator data registers
and protocol required for transmitting monitoring information and required
control.
PLC Network Submittals:
First Submittal
PLC Input/Output List.
PLC Hardware and software, Ethernet Switch, and Operator
Interface Terminal (OIT) specifications with catalogue cut sheets.
Control panel Layout with overall dimensions, Panel NEMA rating,
Panel exterior color, and layout of external and internal mounted
components.
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Submit heat dissipation calculations for every control panel listing
all heat loads, appropriate ambient temperatures, and required
cooling.
Loop Diagrams.
Interconnection wiring diagrams.
PLC Soft link Input/Output List (Made available in Contiguous
Registers) for Control/Owner’s HMI.
Second Submittal (Furnish as one single submittal)
Hard copy of the PLC Application program (Programming software
manual) with explanation of conventions used.
Soft Copy of the PLC Application program with comments on CD-
ROM.
Hard copy of Color graphics, alarm lists, reports & trends.
This submittal shall also include screen shots of all OIT graphic screens and
complete PLC database including specific data register mapping required for
the SCADA Instrumentation Contractorto establish Ethernet mapping for
remote monitoring and control as shown in the Drawings and specified herein.
Complete Operation and Maintenance (O&M) Manuals shallbe provided per Division1
requirements and shallinclude complete O&M information for all components of the
system. O&M Manuals shallbe submitted at leastthirty(30)days prior to final
acceptance of the system. In addition to standard information, the O&M manuals
shallinclude:
Scrubber media handling information and safety data sheet, including
replacement procedures.
Certification statement from manufacturer verifying that the media is
nonhazardous.
Blower sizing calculations. These shallinclude calculations of pressure loss
through the proposed synthetic media, and losses through the system.
Complete point-to-point wiring diagrams. Complete component bill of material
with manufacturers catalog cut sheets marked to show components provided.
Submit copies of final PLC and OIT program versions in native format.
Partial or incomplete submittals will not be reviewed. Any exceptions from this specification
shallbe itemized in an exceptions table.
Information Submittals:
Field Representative Resume
Qualifications Statement
Previous Installations List
Pre-Installation, Special Shipping, Delivery, Storage and Protection, and Handling
Instructions
Manufacturer’s instructions for installation.
Recommended Equipment Lubricants
Samples
Certificates
Software
Manufacturer’s Certification of Compliance.
Manufacturer’s Certificate of Proper Installation.
Location and contact information of nearest stocking distributor of spare parts.
Suggested spare parts list to maintain the equipment in service for a period of one
year. Include a list of special tools required for checking, testing, parts replacement,
and maintenance, with current pricing information.
Welding certificates.
Startup and test schedule.
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Source quality-control reports.
Field quality-control reports.
Closeout Submittals
Paint
Lubricants
Spare Parts
Operation and Maintenance Data
Warranty Documentation
Record Data Documentation
Extra Stock Materials
Tools and Software
1.5QUALITY ASSURANCE
Manufacturer Qualifications: The biological tower-typeodor control system
MANUFACTURER/ EQUIPMENT SUPPLIERshall be one recognized and established in the
design, production, and manufacturing of biological odor control systems. The biological
odor controlMANUFACTURER/ EQUIPMENT SUPPLIERshall have experience in design and
fabrication of similar systems operating in similar applications as demonstrated by a list of at
least 5 successful installations in continuous operation for at least 5 years, with at least 99-
percent hydrogen sulfide removal efficiency. References must include valid names and
phone contact numbers that can be verified.
The MANUFACTURER/ EQUIPMENT SUPPLIERshallprovide an installation report prior to
final acceptance. In addition to the requirements of Division 1,the equipment installation
report shallstate that biological treatment system is achieving the specified removal
efficiencies. Test data on the installed system shallbe included in the report.
All equipment of each type specified in this section shallbe supplied by a single OCS
Supplier and shallbe the product of manufacturers regularly engaged in the design and
manufacturing of biological odor scrubbing equipment. The OCS EQUIPMENT SUPPLIER, in
coordination with the Foul Air Blowers manufacturer shall be responsible for supplying a
complete,functioning system.
MANUFACTURER shall maintain a complete stock of spare parts commonly needed for the
equipment specified at a location within 500 miles of Corpus Christi, Texasor shall be able
to deliver the spare parts within 48 hours of notification.
All pieces of equipment shallhave a Type 316 stainless steel manufacturer’s nameplate
securely affixed in a conspicuous place on the equipment showing the ratings, serial
number, model number, manufacturer and other pertinent nameplate data.
Upon completion of the installation, each piece of equipment and the system shallbe tested
for satisfactory operation without excessive noise, vibration, overheating, etc. All equipment
must be adjusted and checked, for misalignment, clearances, supports, and adherence to
safety standards. Excessive vibration or noise from equipment while operating will be cause
for rejection of equipment.
Performance testing shallbe conducted as specified herein, and per Section 01 75 25
“Equipment Testing and Startup.”
Post installation Inspection: EQUIPMENT SUPPLIERshall provide a field representative to
inspect the system eleven (11) months after substantial completion of the entire project and
shall submit an inspection report within seven(7)calendar days of each inspection.
Where indicated in the Drawings and this Section, all Type 316 stainless steel materials shall
include the follow components:
Molybdenum: 2 –3%
Chromium: 16 –18%
Nickel: 10 –14%
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1.6DELIVERY, STORAGE AND HANDLING
Delivery, storage and handling shallbe in full accordance with EQUIPMENT SUPPLIER'S
instructions. Fabricated assemblies shallbe shipped in the largest sections permitted by
carrier regulations, properly match-marked for ease of field erection.
Motors shall be stored as indicated Section 26 20 00.01,“NEMA Frame Induction Motors,
600 Volts and Below.”
Control Panels shall be stored as indicated in Section 40 05 91,“Common Control Panel
Requirements for Process Equipment.”
1.7SITE CONDITIONS
The equipment, sizes, materials, and arrangements described in this section are based on
recommendations by equipment suppliers and shall be considered minimum limits of
acceptability. The EQUIPMENT SUPPLIER shall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
Environmental Conditions:
All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipal wastewater treatment plants.
All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 120°F.
Equipment shall be compatible with heat tracing and insulation, which will be
furnished and installed by the CONTRACTOR. EQUIPMENT SUPPLIER shall design
piping systems with ample clearances and material compatibility to accept required
heat tracing and insulation. If additional freeze protection beyond heat tracing and
insulation is required it shall be furnished by the EQUIPMENT SUPPLIER. EQUIPMENT
SUPPLIER shall coordinate with the CONTRACTOR to provide direction on where heat
tracing is required, and shall verify that the CONTRACTOR has provided adequate
heat tracing and insulation during startup activities.
1.8WARRANTY
Extended Equipment Warranty: Refer to Section 017836,“Warranties”, Paragraph1.4 for
Special Equipment Warranty.
All equipment furnished under this Section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
Media: Special media warranty shallbe for ten (10)years from final acceptance of the odor
control equipment and shallprovide for complete replacement of the media, including
equipment, materials, labor, freight, and any and all costs associated with washing,
replacing or regenerating the media as needed. Media failure includes increase in pressure
drop through the media such that the specified airflow rates are not achievable with the
installed equipment.
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PRODUCTS
2.1MANUFACTURERS
Manufacturers: Subject to compliance withall specifiedrequirements, available
manufacturers offering products include the following:Manufacturers: The EQUIPMENT
SUPPLIER shall be capable of supplying a complete system in accordance with Paragraph
5
1.1, Item A.1 of this Section. Subject to compliance with all specified requirements and in
coordination with Section 44 3116 "Carbon Adsorber Odor Control System", available
manufacturers offering products include the following:
BioAir Solutions, LLC
Daniel Mechanical Company
6
Evoqua Water Technologies
Biorem Technologies, Inc.
Eco-Verde, LLC
5
Met-Pro Environmental Air Solutions (Bio-Pro System)
2.2PERFORMANCE AND DESIGN REQUIREMENTS
Source Characteristics for the New Broadway Wastewater Treatment Plant
Resaca Lift Station
Expected odorant composition is given in Table 1.
TABLE 1: PERFORMANCE AND DESIGN REQUIREMENTS
Foul Air ParametersValue or Range
Foul Air FlowRate2,700cubic feet per minute (cfm)
Average Inlet Hydrogen
250parts per million (ppm)
Sulfide Concentration Range
Inlet Hydrogen Sulfide
1,500ppm
Concentration Transient Peak
Other Inlet OdorantsReduced Sulfides, Mercaptans, Skatoles, Indoles, Amines
Ambient Air Temperature0-
Empty Bed Residence Time
14 seconds, minimum15 seconds, minimum
(EBRT)
5
Maximum Pressure Drop
4.0inches w.c., maximum
(from inlet to outlet flanges)
Removal requirements:
Refer to Paragraph 3.3 of this Sectionfor additional performance testing
requirements.
Biological Tower-Type Odor Control System Guarantee(at the Typical Operating
Condition):
Average HS Removal: Minimum ninety-nine percent (99%) of inlet hydrogen
sulfide, or the outlet concentration shall be less than 0.5 ppm, whichever is
higher.
Average Odor Removal: For inlet dilution-to-threshold (D/T) concentrations,
minimum ninety-percent (90%) odor removalat the outlet is required, or the
outlet D/T shall be less than 1,500 DT, whichever is greater. For influent odors
with D/T concentrations equal to or greater than the laboratory’s maximum
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value of 60,000, thesample may be dilutedwith nitrogen gas (per laboratory
recommended procedures)to obtain measurablevalues.
2.3BIOLOGICAL TOWER-TYPE ODOR CONTROL SYSTEM
For the OCSspecified, the EQUIPMENT SUPPLIERshall:
Supply all materials and equipment exposed to the airstream, condensate, or leachate
with protection from corrosion damage. Corrosion resistant materials and equipment
are required unless specifically permitted in this Section.
Obtain approval from the OWNER or OWNER’s representative for all coatings to be
used in the completed installation.
Provide an OCSthat operates using biological processes and does not rely oncarbon
either integrated within the media or as a polishing stagefor meeting the specified
performancefor the biological tower-type OCS.
Provide sampling ports (minimum 1-inch diameter) for the inlet, exhaust,anda
minimum of one(1) intermediate stage to measure airflows and airstream
constituents. Ports shallbe easily accessible by OWNER’S personnel and shallbe
routed to ground level. Provide a pressure gauge to measure the pressure in the
distribution plenum at the base of the scrubber unit. Sample ports routed to ground
level shall include a drip leg with ball valve. Provide a ball valve on the end of the
sample line.
Provide sample ports with ball valves on condensate and leachate drains to manually
measure pH. Ports shallbe easily accessible by OWNER’s personnel. Provide pH
probes in the locations as designated on the Drawingsor as approved by Engineer.
The OCS shall not rely on pH measurement for system control.
Supply a neoprene or felt pad for placement under the bioscrubber vessel (minimum
1/8” thick), if required by the manufacturer.
Provide vertical pipe supports and FRP buildup for the discharge piping adjacent to
the bioscrubber vessel. Supportsshall meet the requirements of Detail 229 in the
Contract Drawings.Provide FRP buildup and vertical pipe supports for irrigation and
5
sample piping, as shown on the Drawings (including piping insulation, as needed).
The media support system shall be a sloFed beam or a vinyl ester FRP grate, suitable
for suppor2ng a bed of tower media under all condi2ons of opera2on, including a
6
ooded bed condi2on. Media support system shall be constructed of corrosion-
resistant materials.
Structured Media
The structured media shall be EcoBase®, high porosity, chemically resistant,
engineered, plas2c, synthe2c porous material made from polyvinyl chloride,
polyethylene or polyurethane.
The media characteris2cs (available surface area, density, and pressure drop)
shall be structured and uniform throughout the media bed with pre-
and a void opening of more than 96%. Pressure drop shall not exceed 0.01”
The media shall be guaranteed not to clog or require cleaning, scrubbing,
backwashing, acid-washing or replacement for a period of ten (10) years.
Media beds / stages shall be self-suppor2ng, enclosed in a shell or otherwise
removal as a single piece. Entry into the vessel shall not be necessary for
media removal.
Media shall resist compac2on or swelling due to varying moisture levels and
shall not degrade when subjected to low pH (i.e. pH < 2) condi2ons.
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The uniform structure of the media shall minimize the poten2al for short
6
media cross sec2onal area.
24” height from the boFom of the media is homogeneous at the average
velocity contour plots at 24” media height over the en2re cross sec2on shall be
provided in graphical format as part of the SubmiFal requirements.
listed in sec2on 2.04 are met.
Media shall be pre-installed in the FRP module (s) by the system manufacturer
prior to shipment to the job site.
CONTRACTOR shall:
Provide all hardware, anchors, embedded anchors, and miscellaneous metals that are
Type 316 stainless steel.
CONTRACTOR shall heat trace, insulate, and aluminum jacket all exposed water and
drain lines. Valves and appurtenances shallalso be insulated and heat traced. Air
sample lines are not required to be insulated or heat traced.
Provide field connections between instruments, irrigation systems connections,and
5
panels, as necessary.
All drains from a pressure area shall include a trap with cleanout to be providedand
installedby CONTRACTOR. Trap shall contain a depth of water sufficient to prevent
escape of foul air from the system, as per the standard details.
Vessel Requirements
All materials used in the vessel shallbe inherently corrosion resistant or shallhave a
corrosion-resistant coating. Design drawings for vessel(s) shall be sealed by a
licensed engineer registered in the State of Texas.
Acceptable materials include:
Fiberglass Reinforced Plastic (FRP) vinyl ester resin in accordance with ASME
RTP-1.
Provide gel coat on all surfaces and UV inhibitor on all external surfaces.
Submit certificate from the vessel manufacturer listing the nomenclature,
composition, and characteristics of the resin, as well as vessel and
support calculations.
Minimum Properties of Resin(s): The 1/8-inch thick unfilled clear casting
strength properties of the resin used will affect the total laminate
strength and service life. The following are minimum acceptable room
temperature (77°F) properties for vinyl ester resin:
PropertyVinyl Ester Resin
Tensile Strength11,000 psi
Tensile Modulus490,000 psi
Elongation5%
Flexural Strength160,000 psi
Flexural Modulus450,000 psi
Heat Distortion Temperature210°F
Barcol Hardness35
Grade 316L stainless steel.
Hastelloy C.
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Other materials may be utilized on a case-by-case basis subject to approval by
OWNER and its ENGINEER.
Design of system shallbe in accordance with applicable local, state, and national
standards and codes. Provide an aluminum or FRP ladder with cage and landings
fastened to each scrubber used to access the exhaust stack.
Tank shall meet the following loading criteria:
Wind load limit when anchored:
Ultimate Design Wind Speed; V= 153 mph
ult
Nominal Design Wind Speed; V= 119 mph
asd
Risk Category: III
Exposure: C
Concentrated top load limit: 250 lb. on a 16 square inch area.
Seismic zone: Refer to Drawings for Seismic Design Requirements.
Vessel design shall include reinforcement as required for equipment, CONTRACTOR
furnished pipe supports, accessories, and hose station anchor locations,per support
manufacturer requirements, and as shown on the Drawings. CONTRACTORshall
coordinate reinforcement locations with MANUFACTURER/ EQUIPMENT SUPPLIER.
Irrigation system: The system shallinclude an irrigation system.
Irrigation system shallprovide water for biological activity. Irrigation shall be
monitored and controlled by the PLC, as appropriate for the Manufacturer’s process.
The PLC shall be capable of remote adjustment of irrigation flow.
All exposed irrigation piping shall include insulation and heat tracing provided and
installed by the CONTRACTOR to protect against freezing weather conditions.
Indicate in the submittal what the water requirements are for operation, including
water type (potable/non-potable) and maximum instantaneous flow rate in gallons
per minute (gpm). Provide an in-line filter or strainer on the water supply line.
At the discharge stack of the tower, provide a mist eliminator to minimize carryover of
water particles into the discharge stream.
At the discharge stack of the tower, provide a tee with removable blind flange, as
shown on the Drawings, for access.
Nutrient system: When required, the system shall include a nutrient system.
The nutrient system shall supply nutrients to the irrigation water to promote biological
activity. If the irrigation water does not contain sufficient nutrients to promote
biological activity, a nutrient system shall be included.
The EQUIPMENT SUPPLIER, except where indicated,shall furnishall components
necessary to provide nutrients to the irrigation water, including but not limited to:
One (1) nutrient tank.
The nutrient tank shall have a volume of 55-gallons.
The nutrient tank shall have a level indicator that is tied to the plant
control system as described in Paragraph 2.4 in this Section. The level
indicator will allow plant personnel to monitor the nutrient level in the
tank.
One (1) nutrient feed pump. The pump shall be capable of manual or remote
operation through the plant control system as described in Paragraph 2.4 in
this Section.
Nutrient supply as described in Paragraph 2.7.A.2 in this Section.
Piping, provided and installed by the CONTRACTOR,to connect the nutrient
tank to the nutrient feed pump and to the irrigation system.
The nutrient feed tank and piping shall have insulation and heat tracing, provided,
and installed by the CONTRACTOR,to protect against freezing weather conditions.
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Recirculation system:
For the OCSspecified, recirculation shall only be provided at start-up. During normal
operation, irrigation water shall not be recirculatedand function as a once-through
system.
The recirculation system shall meet the following requirements:
The recirculation system shall take irrigation water that has passed through the
biotrickling filter and pump this water back to the top of the unit to be passed
through the system again. The recirculation system shall consist of the
following components at a minimum:
One (1) recirculation pump. The recirculation pump shall be sized to
pump the drain water from the system back to the top of the system and
maintain the required water pressure. The pump shall be connected to
the plant control system as described in Paragraph 2.4 in this Section,so
that manual and remote operations are possible. A wye strainer shall be
provided for the pump.
Piping to collect the drain water, connect to the recirculation pump, and
convey the recirculated water to the top of the system. All piping shall
have insulation and heat tracing to protect against freezing
temperatures.Piping, insulation,heat tracing shall be provided and
installed by the CONTRACTOR.
Water panel: the system shall include a water panelprovided by the EQUIPMENT SUPPLIER.
The water panel shall serve to connect the irrigation system with the nutrient system
and recirculation system. The recirculation system shall operate during the start-up
phase only.
Where the irrigation system line enters the water panel, a check valve and wye
strainer shall be provided.
Valvesand controls shall be provided to allow for only recirculated or non-recirculated
water to pass through the water panel to the top of the system.
A drain line shall be provided for emergency cases.
A motor operated valve shall be supplied for the irrigation line. This valve shall be
connected to the plant control system as described in Paragraph 2.4 in this Section.
All piping in the water panel shall have insulation and heat tracingto protect against
freezing weather conditions, which shall be provided and installed by the
CONTRACTOR.
Particulate removal: EQUIPMENT SUPPLIER’sdesign shallconsider particulates such as
wind-blown dust that may be present in the airstream and shallprovide for their removal if
equipment performance shallbe hampered by their presence.
Comply with the requirements of Section 099100, “Painting and Protective Coatings.”
Finish colors shall be selected by OWNER from finish color charts to be provided in shop
drawing submittals.
2.4CONTROL PANELS AND INSTRUMENTATION
All instrumentation, control and,electrical components provided under this section shall
comply with the requirements on the Drawings and Divisions 26 and 40.
Refer to Section 40 63 00, “PLC Hardware and Software”, Section 40 66 00, “Network
Equipment”, and 40 70 00 “Field Instruments” for detailed control system requirements.
Control Panels
General requirements for each OCS:
Refer to Section 40 05 91,“Common Control Panel Requirements for Process
Equipment” for general requirements of control panels requirements. Control
panel shall be provided with main circuit breaker, PLC, OIT, starters, control
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power transformer, lights, switches, relays, terminal strips, etc. for a complete
and operational system. The EQUIPMENT SUPPLIER shall provide all additional
instrumentation and controls necessary to produce a safe and operable system.
Control Panel shall be furnished fully assembled, wired, and pre-programmed in
a NEMA 4Xand UL certifiedType 316stainless steelenclosurewith a three
point latching handle and rated for 480 V, 3-Phase, 60 hz.
Control Panel shall be sized to accommodate the equipment required to
achieve the specified functionality, and the following network equipment
to be provided by CONTRACTOR. Equipment supplier is not responsible
for furnishing this network equipment.
Moxa EDS-508Aethernet switch and SFP modules.
CorningWIC-02P Fiber-optic patch panel and fiber-optic cables.
Outdoor Control Panel shall be furnished with a sunshadeif mounted in
direct sunlight. Sunshadeshall include standoffs to allow air circulation
around the panel. Sunshields shall be sized to allow a minimum or 6”
clearance on each side of panel.
Control panel shall include an uninterruptible power supply(UPS)manufactured
by APC, SRT1500XLA. Include APC Dry Contact I/O SmartSlot Card.
Monitor the following dry contacts from the UPS:
UPS On Battery Power.
UPS Fault.
UPS Low Battery Alarm.
In addition to the basic warranty, the UPS manufacturer shall warrant the
batteries for a period of 36 months from the date of equipment start-up or 42
months from date of receipt by end user, whichever occurs first.
Provide power for water panel. Water panel shall have its own protected circuit.
Provide panel drip leg to drain off any moisture accumulated inside control
panel.
Provide thermostatically and humidity-controlled heaters and close loop air
conditioning in the panel if required to maintain proper operating temperature
range for the equipment minimize condensation.
All internal components shall be mounted and secured to the removable back
plane assembly.
Control panel furnished for each OCSshall be provided with one (1) PLC based
control system with operator interface terminal(OIT)furnished by the
EQUIPMENT SUPPLIER. OCSshall be furnished, configured,and completely
commissioned by EQUIPMENT SUPPLIER.
PLC shall be Allen-Bradley CompactLogix or Allen-Bradley ControlLogix.
PLC shall be programmed using Studio 5000 v34 and the PlantPAx
Object Library v5.
OIT shall be Allen-Bradley PanelView Plus 7, 15”. OIT shall be
programmed using FactoryTalk ME v13.
The Operator Interface Terminals shall have a 32Mb flash EPROM
memory and a Compact Flash expansion memory slot. A Compact
Flash card shall be provided with each OIT supplied.
Provide NEMA 4X Type 316 stainless steel OIT window kits to cover the OIT.
The OIT window kitsshall have oil resistant gasket for water tight seal for
outdoor application.
Plant Control System (SCADA) Interface:
The odor control system PLC shall be capable of communicating all
instrument readings and system alarms to the plant control system via
Ethernet/IP multimode fiber optic connection.
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The foul air fans, recirculation pump(for the start-up phase), nutrient
feed pump(if used), and applicable valves shall have ON/OFF indicators
in the SCADA interface.
All odor control system PLC registers shall be made available to the plant
control system integrator.
The EQUIPMENT SUPPLIER shall provide complete electronic copies of all
PLC, I/O,and configuration program data before shipment of the
equipment for use in configuring the plant control system and shall
provide updated versions of this information during the field
commissioning start up and testing, if necessary, including final version
before acceptance of the system. EQUIPMENT SUPPLIER shall supply the
software program and all necessary software components compatible
with the PLC to provide the Owner with the capability to troubleshoot
PLC.
Provide control system for equipment system, but not limited to the odor
control fans, recirculation pump(for the start-up phase only), nutrient feed
pump(if used),and required valves. This list is not intended to completely
depict all of the functional requirements of the control system provided under
this Section. The EQUIPMENT SUPPLIER shall provide all additional
instrumentation and controls necessary to produce a safe and operable system.
Panel shall have the following controls mounted on the panel face:
ON/OFF/AUTOMATIC for each piece of equipment
ON allows the equipment to be started from the panel
OFF allows the equipment to be stopped from the panel
AUTO allows the equipment to be started, stopped, from the
described sequence of operation
OPEN/CLOSE/AUTOMATIC for each valve
OPEN allows the valve to be opened from the panel
CLOSE allows the valve to be closed from the panel
AUTO allows the valve to be opened, closed, from the described
sequence of operation
RUN, FAIL, and OFF push-to-test LED indicating lights for each piece of
equipment.
Fail reset button for each piece of equipment
Power On indication light
OIT color touch screen
The minimum shall be provided with the panel:
Main circuit protective device
PLC with Ethernet/IP communications.
NEMA rated contractors for each piece of equipment
Fused sealed oversized control power transformer.
Combined sounder and LED beacon for annunciating of failure.
Beacon/horn shall be mounted separately from enclosure by
CONTRACTOR.
Ambient temperature controlled.
Condensate drain.
Provide engraved nameplates for each function.
Provide terminal strips in enclosure for termination of device, no direct
termination to relays, starters, etc. allowed.
One(1) temperature sensor shall be mounted inside control panel to
continuously sense the temperature of control panel. The reading shall
be displayed on the OITpanel and relayed to the SCADA system.
Sequence of Operation
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Generaldescription for each OCS provided:
The OCSis a stand-alone control system monitored by the Plant PCS
System. The control panel provides monitoring and manual control
through the panel’s OIT and is used by the Plant Operators to make
adjustments tothefoul air fansand bioscrubber controls. All monitoring
and control shall be from the OIT.
Fansshall restart upon power restoration after delay. The PLC shall
monitor normal power source and shall restart blowers upon delay.
All control actions at the OCScontrol panel are performed using the
Odor Control PLC.
Control Panel Wiring and Assembly
All controlenclosures shall be custom assembled and wired in an Underwriters
5
Laboratories (UL) certified cabinet shop using quality materials and labor.
All control panel wire shall be multi-strand tinned-copper machine tool wire minimum,
with MTW insulation. Discrete IO cable shall be No. 14 AWG and analog IO cable
shall be No. 16 TSP shielded cable. Wire colors are as follows:
230 VAC or higherBlack
120 VAC control powerRed
NeutralWhite
GroundGreen
Power from remote sourceYellow
24 VDC (+)Orange
24 VDC (-)Gray
All wires shall be clearly marked with an identification number consistent with the
wiring schematic drawing.
Wiring inside the control panel shall be run in white PVC wiring duct rated for
continuous temperatures up to 140ºF. Devices mounted in the enclosure door shall
have wires run in spiral wrap to avoid pinch points when opening and closing the
door.
Control components mounted internal and external to the enclosure shall be mounted
with Type 316 stainless steel hardware and clearly labeled with a plastic identification
nametag. The tag shall be white with black lettering.
5
Control panels, as well as components installed, shall comply with environmental
fabrication requirements of Specification Section 40 05 91“Common Control Panel
Requirements.”
All wiring outside panels shall have XHHW-2 insulation. Wiring and conduits shall be
sized to meet NEC 2020Code.
Provide intrinsically safe barriers on signal circuits interfacing with hazardous areas as
shown on the Drawings.
Field Instrumentation
General Requirements
Section includes field instruments, unscheduled devices, auxiliary equipment
and installation components required for an installation and operational
devices. As part of this system, the instruments specified in this Section shall
be provided by the EQUIPMENT SUPPLIER.
The manufacturer of this equipment shall have produced similar equipment for
a minimum period of five (5) years. When requested by the
OWNER/ENGINEER, an acceptable list of installations with similar equipment
shall be provided demonstrating compliance with this requirement.
Unscheduled Devices
Provide stainless steel 1/2”ballvalves when indicated in P&IDs.
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Provide diaphragm pressure seals when indicated in P&IDs.
Provide instrument manifolds for all static pressure, liquid level and
differential pressure application.
Provide an external weatherproof on-off switch for each instrument
obtaining power from an external power source (non-loop powered).
Provide field surge protection on all 4-20ma instrument signals.
Protection device shall be NEMA 4X and installed in accordance with
manufacturer’s recommendations.
Provide sun-shields on all transmitters mounted outdoors.
Commissioning:
Commissioning of instruments shall be in accordance with
manufacturers’ instructions, the product data and shop drawings and
Division 1 specifications.
Instrumentation
Paddlewheel Flow Meter
Description: Flow sensor shall be Microprocessor-based Pulsed DC
electromagnetic induction type providing a signal which is linear to the
flow rate of a conductive liquid in a full pipe. Use of insert flow meters or
multiple single point probes inserted into a spool piece is unacceptable.
Function:
Accuracy: +/-0.5 percent of rate for velocities of 1 to 30 fps.
Turndown: 10:1 minimum, at flow rates above 1 fps.
Outputs: Compatible with supplied odor control PLC.
Display: Digital indicator scalable to flow rate engineering units or
0-100 percent.
Physical:
Material: As suitable for the process area.
Quantity: 1
FIT-4100
Differential Pressure Transmitter
Description: Transmitter shall be Microprocessor-based, intelligent type
to measure differential pressure.
Function:
Output: 4-20 mA DC with HART protocol.
Power: Loop powered, compatible with intrinsically safe barrier.
Physical:
Housing: cast aluminum.
Transmitter enclosure: NEMA4X
Quantity: 3
PDIT-4200
PDIT-4401
PDIT-4402
Side Mount Level Switch
Description: Horizontally mounted level switch, rated NEMA 6. Switch
shall be SPST, rated at 50 VA. Switch shall be constructed of CPVC.
Manufacturer and model: Omega, LVN-90.
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Quantity: 2
LSL-4100
LSL-4200
Pressure Indicating Transmitter
Description: Transmitter shall be constructed on die cast aluminum, with
a LCD, 4-20 mA (Hart) output signal, 24 VDC loop powered, and ceramic
diaphragm. Manufacturer and model, Endress+Hauser PMC71.
Quantity: 1
FIT-4100
2.5FINISHES
All equipment except stainless steel, galvanized steel, PVC, or non-ferrous items identified as
non-corrosive by Manufacturer shall receive surface preparation, prime coat,and finish coat
to the Supplier’s specifications, in the factory. Provide one (1)gallon of touch up paint.
Paint shall comply with the requirements described in Section 099100,“Paintingand
Protective Coatings.”
Furnish equipment with corrosion protection compounds for unfinished items.
All panels containing heat sensitive equipment shall be factory painted white.
2.6ACCESSORIES
Anchor Bolts: Provide template and Type 316 stainless steel anchors and fasteners in
accordance with Section 05 05 23,“Metal Fastenings and Anchor Bolts”, as shown on the
Drawings, and as recommended by the EQUIPMENT SUPPLIER. Size and locations as
required by EQUIPMENT SUPPLIER. EQUIPMENT SUPPLIER shall size all anchor bolts and
fasteners required of ample size and strength for the intended purpose, minimum of ½-inch
diameter. Fastener sizing calculations shall be provided as an informational submittal.
CONTRACTOR shall furnish and install all anchor bolts and fasteners in accordance with the
equipment supplier’s installation instructions.
Equipment Identification Plates: EQUIPMENT SUPPLIER shall furnish a 16-gauge stainless
steel identification plate securely mounted on the equipment in a readily visible location. The
plate shall bear 1/4-inch die-stamped equipment identification number indicated in this
Section and/or on the Drawings.
Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 60
pounds shall be provided with lifting lugs
Initial Supply of Lubricants: EQUIPMENT SUPPLIER shall indicate types, brands, and
quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants and shall comply with all
equipment supplier recommended procedures.
2.7TOOLS, SPARE PARTS,AND MAINTENANCE MATERIALS
Initial Supply of Consumables
EQUIPMENT SUPPLIER shall furnish and indicate types, brands, and quantities of
initial lubricants, oil, grease, nutrient solutions, biological seeding material, etc.
necessary to startup equipment. EQUIPMENT SUPPLIER shall provide and install the
recommended lubricants and shall comply with all manufacturer recommended
procedures.
If nutrients are required for operation, EQUIPMENT SUPPLIER shall provide a one-
year supply (beginning at acceptance of the odor control unit) of nutrients in addition
to supplies for startup and testing. Refer to the New Broadway Wastewater Treatment
Plant effluent water quality, provided after the END OF SECTION.
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The EQUIPMENT SUPPLIER shall supply one (1) set of spare parts for all components
exposed to operational wear during normal equipment service.
One (1) set of special tools required for maintenance or adjustment.
Two (2)sets of fuses of each type used.
Two (2) spare relays of each type used.
One (1) spare bulbof each type used on panel fronts.
One (1) set of spare parts for the nutrient feed pump(if used).
Two (2) sets of strainers for each type supplied.
Other items as recommended by the Manufacturer and EQUIPMENT SUPPLIER.
Equipment Lubricants: The EQUIPMENT SUPPLIER shall indicate and verify types, brands,
and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants.
Spare parts shall be packed in sturdy containers with clear, indelible identification markings
and shall be stored in a dry, warm location until transferred to the OWNER at the conclusion
of the project. Each part shall be labeled with part numbers which correspond to the
Operation and Maintenance Data submitted in accordance with Section 01 78 23,“Operation
and Maintenance Data.”
EXECUTION
3.1FABRICATION AND FACTORY TESTING
The procedure shall consist of the Test Plan submittal and the Testing, and shall comply
with Section 01 75 25, “Equipment Testing and Startup.” In the Test Plan submittal, the
approach to testing is stated along with a description of the general approach to testing all
functions. This plan gives the reader a good idea of how the testing will be conducted. The
details of the testing are in the Testing Sections. The Test Plan submittal shall include the
following:
Purpose
References
Test Environment Statement
Procedure
Test Section Checklist
The body of the Factory Testing is split into sections around similar functional test areas.
The sections contain a minimal amount of description of the testing with the great majority
dedicated to recording the data. Each section includes the following:
Test Number.
Test Purpose.
Acceptance Criteria.
Detailed Test Procedure.
Data Collection Portion of the Form.
Comments Section.
Signature Block.
Date Block.
Approval Block.
All major system controls for the Odor Control Systemsshall be factory tested for
compliance with the construction and functional requirements specified herein and a report
of the results of these tests shall be submitted in writing to the ENGINEERfor each control
panel separately, prior to shipment.
All PLC and OIT programming shall be performed at the factory. Certification of test results
shall be submitted to the OWNER and ENGINEER.
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Factory testing shall consist of an Unwitnessed Factory Test (UFT)and Witnessed Factory
Acceptance Test (FAT).
Provide test procedure and report. The test procedure and report shall include each input
and output, and each function test procedure and reports for test result documentation.
SUPPLIERshall notify the OWNER and ENGINEERof the successful completion of the UFT.
Examples of testing sections are as follows:
Panel wiring.
Panel power on operational test.
I/O check from panels through the software.
Testing of manual operations.
Testing of functional modules of programming (automatic and sequencing).
Trending and Alarm verification.
Security.
Power loss and restoration.
OIT and graphics shall be tested.
Successful completion of UFT and approval by the ENGINEERare required prior to schedule
Witnessed factory acceptance test
Witness Factory Acceptance Test
Provide FAT at the manufacturer’s facility for all equipment inspection and control
panel PLC/OIT programming and configuration test. This FAT shall also provide
SCADA HMI and control panel PLC data IO checking and function test. The FAT will
also test the water panel. SCADA Instrumentation contractor will also participatein
FAT and bring their development laptops for control panel PLC, SCADA HMI
communication and configuration test.
The FAT shall be scheduled for minimum 3-day test to perform all tests. This 3-day
test shall not include travel time.
MANUFACTURER shall provide two (2) people, one from the OWNER’s Construction
Management Services and one ENGINEER’s representative, for their travel from
Dallas/Fort Worthto the FAT facility. The travel expense shall include round trip direct
flight tickets, rental cars, hotel and $60/day meal.
If the FAT is not accepted, MANUFACTURER shall redo the FAT until the test is
accepted. The MANUFACTURER shall provide all travel expenses for additional FATs.
Retainage of payment shall be withheld until successful completion of FAT and approval of
PLC programming as described herein.
3.2INSTALLATION
CONTRACTOR to install equipment per this Section and the EQUIPMENT SUPPLIER’s
installation instructions.
3.3FIELD / SITE QUALITY CONTROL
EQUIPMENT SUPPLIER’s Representative: The EQUIPMENT SUPPLIER Field Representative
shall be present at Project site or classroom designated by OWNER, for minimum person-
days listed in the table below. Each person-day shall be defined as eight (8) hours duration,
exclusive of travel. The EQUIPMENT SUPPLIER Field Representative shall revisit the jobsite
as often as necessary to correct deficiencies:
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TABLE 2: EQUIPMENT SUPPLIER’S SERVICES
Work DescriptionNo. Person DaysNo. Trips
Installation assistance and inspection21
Functional and performance testing1Can be combined with training
Pre-startup classroom or site training11
Facility startup2Can be combined with training
Post-startup training of OWNER’s personnel11
EQUIPMENT SUPPLIER’s services shall comply with the requirements of Section 017525,
“Equipment Testing and Startup.”
The EQUIPMENT SUPPLIERshall furnish a qualified startup engineer or field representative
to provide guidance with installation. The field representative shallalso inspect all
equipment described herein after installation, assist in troubleshooting, advise the
CONTRACTOR during startup and testing, and instruct OWNER's personnel in routine
maintenance and troubleshooting procedures. Working days shallconsist of eight-hour (8-
hr) days, exclusive of travel time. The EQUIPMENT SUPPLIERshallcoordinate the
scheduling of such training and startup assistance with OWNER’S personnel. OWNER may
videotape training session.
Two training sessions shall be performed, one in the early morning and one in the late
afternoon. CONTRACTOR shall coordinate the scheduling of such training and start-up
assistance with the OWNER’s personnel. OWNER may videotape training session. A typed
outline shall be handed out at the training sessions and, at a minimum, will include normal
operating parameters, alarms, and maintenance.
3.4SYSTEM STARTUP
Startup of each OCSshallbe done in accordance with EQUIPMENT SUPPLIER’S
recommendationsand as specified in Section 01 75 25,“Equipment Testing and Startup.”
Each portion of each the OCS shall be testedas specified herein and as indicated in
Section443183,“Foul Air Collection System Testing, Adjusting, and Balancing.” The OCSs
shallbe sampled at the intakeand dischargeof the biological tower-type odor control
system.
In the presence of the OWNER and the OWNER’s engineer, CONTRACTOR shalltest the
operation of each OCS. Final acceptance shallnot be made until after successful completion
of the performance testing and receipt of the final installation report.
Testing Equipment: CONTRACTOR shallsupply the equipment listed below for the duration
of the performance testing. Equipment shallremain on site until performance testing has
been accepted by the OWNER or OWNER’S representative. Submit current calibration
certificates for each piece of equipment used along with test results. CONTRACTOR shall
comply with equipment manufacturer’s recommendations for equipment use.
Jerome 631-X (or newer model) Hydrogen Sulfide Analyzer by Arizona Instruments.
Range 0.003-50 ppm(intended for in-field grab sampling analysis only).
Odalog Hydrogen Sulfide Gas Logger by Detection Instruments. One each Range
0-1000 ppmor 0-200 ppm(adequate range to monitor inlet concentration),and
0-50ppmOdalogs; two low-range 0.001-2.0 ppmOdalogs; one Low-Range Sampling
System (LRSS-2), eachwith sufficient PVC or Teflon hose for testing.
Alnor AXD 540 Micromanometer by TSI Incorporated, Range 250-15,500 fpm, with
18-inch pitot tube and hoses, or equal.
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Accuro gas detector pump by Drager Safety. Include 10 tubes for Hydrogen Sulfide
0-200 ppm.
Odor sampling shall commence one hour after the HS monitoring equipment has
been installed and is determined to be stable. Two (2)sample sets, each consisting
of the bioscrubber inletand outlet. Each sample set shall be taken one hour apart.
The inlet and outlet samplesshall be taken concurrently and the sampling time and
inlet and outlet HS levels loggedin the field prior to shipment. Thefour (4)samples
shall be shipped to the laboratories for analysis to be received within 24 hours. The
analyses and respective laboratories shall include:
ODOR UNITS TESTING:
St.Croix Sensory
1150 Stillwater Blvd. North
Stillwater, MN 55082
1-800-879-9231
REDUCED SULFIDES TESTING:
ALS Environmental (formerly Columbia Analytical Services, Inc.)
2655 Park Center Drive, Suite A
Simi Valley, CA 93065
805-526-7161
Testing Procedure:
Each OCSshall be balanced per Section 44 31 83, “Foul Air Collection System Testing,
Adjusting, and Balancing”,prior to testing.
Measure the airflowvelocity(feet per minute(fpm)), static pressure (inches water
column(in. wc)),and velocity pressure (in. wc) into each odor scrubber/adsorption
unit. Airflows shall be within five percent (5%)of the specified value before testing
may commence.
Measure the airflows into each individual scrubber/adsorption unit. Airflows shall be
within 5% of equal or specified distribution before testing may commence.
Using the Draeger pump and HS tubes, verify the inlet HS concentration is less than
1,000 ppm.
Connect the low range Odalog LRSS-2 tube to the exhaust of each scrubber/
adsorption unit being tested. Connect the high range (0-200 or 0-1000 ppm as
appropriate) Odalog LRSS-2 tube to the foul air collection systemat the inlet of the
biotrickling filter being tested. Coordinate sampling locations with the OWNER or
OWNER’S Representative. Odalogs shallbe set to log time, temperature (°F),and
HS concentration at two-minute intervalsfor high-range Odalogs and ten-minute
intervals for low-range Odalogs. Log data continuously for a minimum of two weeks
for each pair of scrubber/adsorption units. Comply with the Odalog manufacturer’s
instructions and recommendations for use. Odalogs must be logging data during the
duration of the tests. Testing shall comply with Section 017525,“Equipment Testing
and Startup,” and Section 4431 83,“Foul Air Collection System Testing, Adjusting,
and Balancing.”
Using the Jerome 631-X meteror low-range Odalogs, to measure grab samples of
biotrickling filterexhaust HS concentrations in the field prior to sending the samples
to the lab.
Testing Report: CONTRACTOR shallsubmit the followingfor each OCS:
CD-ROM containing the original Odalog data files and files exported into Microsoft
Excel format. Written report shallinclude graphs of Odalog data.
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Dimensioned drawing showing locations and identification of samples taken.
Date, time, sample and results of each sample taken.
Airflow rate, static and velocity pressures at the time of sampling.
Any deviations from the test procedure with an explanation.
Original log of sample information including but not limited to duration of each
sampling event and overall performance test, equipment type used for each sampling
event, type of constituent measured in each sampling event.
Acceptance: Determination of satisfactory performance will be made by the OWNER or
OWNER’S representative based on the above performance testing or additional testing as
needed. Acceptable HS removal will be determined by averaging the continuously logged
inlet HSconcentrations and averaging the continuously logged outletconcentrations
measured by the Jerome meter andOdalogs, as appropriate. Odor sampling shallbe
performed in accordance with ASTM E679 and EN 13729. If the sampling results do not
meet the requirements of Paragraph 2.2.B of this Section,the EQUIPMENT SUPPLIERwill be
given four weeks to make necessary modifications to the OCS(s)before a retest is
conductedat no expense to the OWNER. The OWNER may withhold the cost of any retest
from the CONTRACTOR’s final payment. If the system fails two retests, the EQUIPMENT
SUPPLIERshallremove and replace the OCS(s)with one that meets the requirements, at its
sole cost.
EQUIPMENT SUPPLIERmay conduct concurrent testing at their option at no cost to the
OWNER. Concurrent testing by the EQUIPMENT SUPPLIERwill not be used as a basis for
acceptance of the unit.
All warranty and guarantee periods shall be in accordance with Paragraph 1.8 of this
Section. Performance testing may not begin untileach OCS is connected to the foul air
sources identified in Paragraph 2.2.A in this Section.
In the presence of the OWNER and the Owner’s Representative, the CONTRACTOR shalltest
the operation of each OCS. Final acceptance will not be made until after successful
completion of the performance testing and receipt of the final installation report.
3.5CLOSEOUT ACTIVITIES
A copy of all information from functional tests including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
BIOSCRUBBERCONTROL PANEL PLC/OIT CONFIGURATION AND PROGRAMMING
REQUIREMENTS FOR PLANT SCADA HMI MONITORING.
4.1PLC AND OIT PROGRAM OWNERSHIP
Provide PLC and OIT program full ownership to the Owner. PLC and OIT program shallnot
be locked by any means.
After system is completely tested, CONTRACTORshall provide three copies (CD-ROM) of PLC
and OIT program to the OWNER.
4.2PLC IO MEMORY MAPPING
Provide PLC IO memory mapping to SCADA instrumentation contractor. This IO mapping
shall be used for the scrubber equipment and instruments SCADA HMI monitoring and
control.
The IO mapping shall in excel spreadsheet and has tag name, tag description, data type,
PLC address, instrumentationrange and engineer unit.
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4.3PLC/OIT PROGRAMMING REQUIREMENTS.
Before beginning PLC program design, MANUFACTURER shall contact OWNER (through the
ENGINEER) to determine if specific guidelines or preferences exist. If available, these
guidelines or preferences shall be used to develop the PLC program design.
Instrument reading programming:
Provide instrument reading. Reading shall be converted to engineering value in PLC.
Provide each analog signal reading and reading quality bit. The reading bit shall
indicate that the instrument reading is good or bad.
Provide each instrument SCADA manual override function. This function is to allow
the plant operator to manually enter an override value into PLC when instrument fails
and PLC will take operator manual value for process control.
Equipment programming:
Equipment refers to pump, blower, and not valve.
Provide each equipment lifetimeruntime and starts. This lifetimeruntime and starts
shall be not resettable and are calculated since equipment are in service
Provide each equipment resettable runtime and starts. This runtime and starts can be
reset at OIT or SCADA HMI. This runtime and starts will be used for equipment
maintenance purpose.
Provide equipment resettable runtime and stats reset time stamp for SCADAHMI
display. The reset time stamp shall have year, month, day, day of week, hour,
minute, and second.
Provide equipment last run time stamp for SCADA HMI display. Stamp shall record
each equipment on event and have year, month, day, day of week, hour, minute, and
second.
Provide equipment Any_Fault signal. Any_Fault is a general equipment fault signal
that combines any of equipment fault. This signal will be used for equipment fault
status HMI animation.
Provide equipment fail to start and fail to stop signal, fault timer and fault reset. Fail
to start and stop signals are for HMI display, fail to start and stop timer shall be
changeable on the HMI screen. SCADA and OIT shall also be able to reset these
faults.
Provide equipment deviation fault. This fault occurs when equipment stopped or
running without any local OIT or SCADA run or stop command.
Provide equipment hardware fault. Hardware fault is a combined fault condition for
any of equipment hardware fault, including PLC IO module and input/output
associated with each equipment signal.
Provide equipment Inform/Lockout tag PLC programming. PLC shall provide
equipment operation inform and lockout tag bit. This bit is used to maintain SCADA
equipment inform and lockout command.
Valve equipment programming:
Equipment refers to any control valve.
Provide equipment Any_Fault signal. Any_Fault is a general equipment fault signal
that combines any of equipment fault. This signal will be used for equipment fault
status HMI animation.
Provide equipment fail to open and fail to close signal, fault timer and fault reset. Fail
to open and close signals are for HMI display. Fail to open and close timer shall be
changeable on the HMI screen. SCADA and OIT shall also be able to reset these
faults.
Provide equipment deviation fault. This fault occurs when equipment open or close
without any local OIT or SCADA command.
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Provide equipment hardware fault. Hardware fault is a combined fault condition for
any of equipment hardware fault, including PLC IO module and input/output
associated with each equipment signal.
Provide equipment Inform/Lockout tag PLC programming. PLC shall provide
equipment operation inform and lockout tag bit. This bit is used to maintain SCADA
equipment inform and lockout command.
Other programming requirements:
Provide PLC heart beat signal for SCADA monitoring
Provide PLC NTP configuration to allow PLC clock synchronized with SCADA timer
server. Coordinate with SCADA instrumentation contractor for time server info.
Provide time/date adjust program to allow SCADA HMI to manually change PLC
time/date
OIT programming requirements:
Provide requirement Overview and equipment detail screens.
Coordinate with OWNERfor OIT HMI screen configuration and display requirements.
Requirements include dynamo, color convention, animation, alarm, trending…etc.
Provide three level operation security setting, usernameand password.
Supervisor –administration level for operation
Operator –equipment operation
Visitor –View only
Screen auto logout after 5 minute no event
Screen saving screen. 10 minute no event
Trending screen for each analog signal. Historian log.
Event trending screen for each equipment status change. Historian log
Alarm summary screen.
OIT shall be programmed using FactoryTalk ME v13.
TABLE 3: EFFLUENT WATER QUALITY DATA
EFFLUENT SETS
DESCRIPTION
NH-N TP (mg/L)
3
FLOW (MGD)BOD(mg/L)DO (mg/L)
5
(mg/L)
Existing Water
aabcb
8208.22 –33
Quality Data
a
Average permit limit.
b
Average value from plant’s water quality data.
c
2 mg/L is required for Outfall 001 and 3 mg/L is required for Outfall 002.
END OF SECTION
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5
SECTION 44 31 16
CARBON ADSORBER ODOR CONTROL SYSTEM
GENERAL
1.1SUMMARY
Coordinating Supplier
The EQUIPMENT SUPPLIER ofthe Section 44 31 11, “Biological Tower-Type Odor
Control System” shall be responsible for providing all equipment listed in this
specification section.
Section Includes:
The EQUIPMENT SUPPLIER shall furnish, install, startup, and test one (1) carbon
adsorberodor control unitas specified herein for a complete and operable system.
The carbon adsorber odor control unit shall include the carbon mediaodor control
unit, mist eliminator, rain caps, vessels or containers,activated carbonmedia, inlet air
plenum, and instrumentation.
The proposed system shall treat odors from Resaca Lift Station.
To ensure system compatibility, a single EQUIPMENT SUPPLIER is responsible for
providing a complete system andthe successful operation of eachitem of equipment
in the packageand for the integrated systemwhich also includes Section 43 11 19,
“Foul Air Fans”, and Section 44 31 11, “Biological Tower-type Odor Control System.”
The responsibility of the EQUIPMENT SUPPLIER will include the approval of
installation, system optimization, and warranties for the components and performance
of thecompleteOdor Control System.
1.2REFERENCES
Drawings and general provisions of the Contract, including Special Conditions and Division 1
Specification Sections, apply to this Section.
The following testing procedures will be used to verify performance of the equipment, most
current version:
ASTM E679: Determination of Odor and Taste Threshold by a Forced-Choice.
Ascending Concentration Series Method of Limits.
EN 13725: Air Quality – Determination of Odor Concentration by Dynamic
Olfactometry.
Related Sections:
1.Section 01 33 00, “Submittal Procedures.”
2.Section 01 75 25, “Equipment Testing and Startup.”
3.Section 09 91 00, “Painting and Protective Coatings.”
4.Section 40 05 36.13, “Foul Air Fiberglass Ductwork.”
5.Section 40 05 51, “Common Requirements for Process Valves.”
6.Section 40 73 99, “Pressure Gauges and Thermometers”
7.Section 43 11 19, “Foul Air Fans.”
8.Section 43 31 11, “Biological Tower-Type Odor Control System.”
9.Section 44 31 83, “Foul Air Collection System Testing, Adjusting, and Balancing.”
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1.3ADMINISTRATIVE REQUIREMENTS – NOT USED
1.4SUBMITTALS
Action Submittals
Product Data: Provide construction details, material descriptions, dimensions of
individual components and profiles, rated capacities, operating characteristics,
electrical characteristics, and furnished specialties and accessories.
Shop drawings specific to the project and applicable product data will be bound neatly
in a single package. The following information will be submitted following the award
of contract and issuance of a notice to proceed, as a minimum:
EQUIPMENT SUPPLIER shall provide a copy of this Section and indicate for
each specification item in this Section that the requirement is acknowledged. All
deviations from the contract documents shall be clearly identified in a separate
list.
Manufacturer and model number of equipment.
Safety Data Sheets.
Drawings indicating the layout, size, and all proposed components of the odor
control system, including dimensions, clearances, materials of construction,
material thicknesses, coating, linings, and flow direction.
Layout drawings including all proposed system components with dimensions,
clearances required and sizes indicated, anchor locations and sizes, details of
ductwork or piping connections, size and location of required electrical conduits
and conduit openings, and total weights of the product. Include descriptions
and provisions for adjustments and alarms on operating components. Indicate
extent of shop fabrication and field joint types and locations. Layout drawings
will be to scale in English units, provided on 11”x17” bond paper and on
compact disk in AutoCAD format.
Include flow directions, process information, loading rates, etc., descriptions
and provisions for adjustments and alarms on operating components.
Detailed specifications and data describing the materials of construction,
material thickness and coatings for all components.
Submit data that verifies the system is capable of uniformly distributing flow
throughout the system without short-circuiting and will meet the specified
treatment requirements.
EQUIPMENT SUPPLIER shall provide a list of similar installations with reference
and contact information for operating systems. List shallhave a minimum of
five (5) successful installations of similar size for acceptance and will have at
least five (5) similar systems in continuous operation in similar applications for
three (3) years. Submittals received without current names and phone numbers
for reference contacts may be deemed non-responsive.
Anticipated media life at design conditions and current replacement cost
(material supply only) of media.
Empty bed residence times for proposed and future flows.
Headloss (inches of water column) through the adsorber media, distribution
plenum, and complete unit and odor control system.
All required utility connection points and supply requirements including power
and control wiring.
Location and telephone number of nearest stocking distributor of spare parts.
Startup and test schedule with test procedures.
Equipment installation report with field test data and test records in accordance
with Section 01 33 00, “Submittal Procedures” (submit as record data after
startup).
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Warranties and service agreements.
All structural design calculations, drawings, and associated items shall include
all adsorber vessels items, deflection of the vessel at the point of connection
with the ductwork, thickness, anchor bolt size and location, hold-down lugs,
lifting hooks, and loads imposed by appurtenances such as inlet ducting and
internal media. The OWNER or OWNER’S Representative will review the
structural drawings and calculations for completeness only. All structural
drawings and calculations shall be signed and stamped by a Professional
Engineer (registered in the State of Texas) prior to submittal to the OWNER.
A certificate from the vessel manufacturer listing the nomenclature,
composition, and characteristics of the resin or other plastics shall be supplied
with the submittal data, as well as vessel and support calculations as specified
if fiberglass is used for the adsorber vessel.
Any other information necessary for the OWNER or OWNER’S representative to
determine compliance with the specifications.
Auxiliary Instrumentation and Devices: Datasheets and mounting
locations/details for auxiliary instrumentation and devices furnished with
equipment. The informationshall include associated mounting brackets and
hardware.
Wiring Diagrams: If applicable, for power, signal, and control wiring diagrams,
including terminals and numbers.
Instrumentation and Control Submittals:
P&IDs and Process Flow Diagrams
Instrument specifications in ISA Format with catalogue cut sheets
Instrument list with tag names, ranges, alarm set points, and manufacturer
contact information.
Description of control system in written form including functions monitored,
controlled, and alarmed. Include sequence of operation and interface
requirements.
Complete Operation and Maintenance (O&M) Manuals will be provided per Section
017823,“Operation and Maintenance Data”and Division 1 requirements and will
include complete O&M information for all components of the system. O&M Manuals
will be submitted at least thirty (30)days prior to final acceptance of the system. In
addition to standard information, the O&M manuals will include:
Adsorber media handling information and safety data sheet, including
replacement procedures.
Certification statement from EQUIPMENT SUPPLIER verifying that the media is
nonhazardous.
Fan sizing calculations. These will include calculations of pressure loss through
the proposed media, and losses through the system.
Complete point-to-point wiring diagrams. Complete component bill of material
with manufacturers catalog cut sheets marked to show components provided.
Submit copies of final PLC and OIT program versions in native format.
Operations and Maintenance Data shall also be included with the Manuals in an
electronic (PDF) format on a DVD-ROM for the Owner’s use. Drawing files shall
be in AutoCAD format. Spreadsheets shall be in Microsoft Excel Format, and
shall be electronically indexed for ease of viewing and referencing.
Partial or incomplete submittals will not be reviewed. Any exceptions from this specification
will be itemized in an exceptions table.
Information Submittals:
Field Representative Resume
Qualifications Statement
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Previous Installations List
Pre-Installation, Special Shipping, Delivery, Storage and Protection, and Handling
Instructions
Manufacturer’s instructions for installation.
Recommended Equipment Lubricants
Samples
Certificates
Software
Manufacturer’s Certification of Compliance.
Manufacturer’s Certificate of Proper Installation.
Location and contact information of nearest stocking distributor of spare parts.
Suggested spare parts list to maintain the equipment in service for a period of one
year. Include a list of special tools required for checking, testing, parts replacement,
and maintenance, with current pricing information.
Welding certificates.
Startup and test schedule.
Source quality-control reports.
Field quality-control reports.
Closeout Submittals
Paint
Lubricants
Spare Parts
Operation and Maintenance Data
Warranty Documentation
Record Data Documentation
Extra Stock Materials
Tools and Software
1.5QUALITY ASSURANCE
The EQUIPMENT SUPPLIERwill provide an installation report prior to final acceptance. In
addition to the requirements of Section 01 3300, “Submittal Procedures”, the equipment
installation report will state that the treatment system is achieving the specified removal
efficiencies. Test data on the installed system will be included in the report.
All equipment of each type specified in this section will be supplied by a single EQUIPMENT
SUPPLIER and will be the product of suppliers regularly engaged in the design and
manufacturing of activated carbon odorcontrolequipment. The EQUIPMENT SUPPLIER, in
coordination with the Foul Air Fans and Duct/Damper manufacturer(s) shall be responsible
for supplying a complete functioning system.
EQUIPMENT SUPPLIERshall maintain a complete stock of spare parts commonly needed for
the equipment specified at a location within the State of Texas or will have 48-hour delivery
of spare parts.
All pieces of equipment will have a Type 316 stainless steel manufacturer’s nameplate
securely affixed in a conspicuous place on the equipment showing the ratings, serial
number, model number, manufacturer and other pertinent nameplate data.
Upon completion of the installation, each piece of equipment and the system will be tested
for satisfactory operation without excessive noise, vibration, overheating, etc. All equipment
must be adjusted and checked, for misalignment, clearances, supports, and adherence to
safety standards. Excessive vibration or noise from equipment while operating will be cause
for rejection of equipment.
Performance testing will be conducted as specified herein, and per Section 01 75 25,
“Equipment Testing and Startup.”
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Post installation Inspection: EQUIPMENT SUPPLIERshall provide a field representative to
inspect the system eleven (11) months after substantial completion of the entire project and
shall submit an inspection report within seven (7) calendar days of each inspection.
Where indicated in the Drawings and this Section, all Type 316 stainless steel materials shall
include the following components:
Molybdenum: 2 – 3%
Chromium: 16 – 18%
Nickel: 10 – 14%
1.6DELIVERY, STORAGE AND HANDLING
Deliver, handle, and store all components to be installed under this section in accordance
with the EQUIPMENT SUPPLIER’s written Pre-Installation Delivery, Storage, and Handling
Instructions and the requirements of Section 01 60 00, “Product Requirements.” Fabricated
assemblies will be shipped in the largest sections permitted by carrier regulations, properly
match-marked for ease of field erection.
1.7SITE CONDITIONS
The equipment, sizes, materials, and arrangements described in this section are based on
recommendations by equipment suppliers and shall be considered minimum limits of
acceptability. The EQUIPMENT SUPPLIER shall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
Environmental Conditions:
All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipal wastewater treatment plants.
All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 120°F.
Equipment shall be compatible with heat tracing and insulation, which will be
furnished and installed by the CONTRACTOR. EQUIPMENT SUPPLIER shall design
piping systems with ample clearances and material compatibility to accept required
heat tracing and insulation. If additional freeze protection beyond heat tracing and
insulation is required it shall be furnished by the EQUIPMENT SUPPLIER. EQUIPMENT
SUPPLIER shall coordinate with the CONTRACTOR to provide direction on where heat
tracing is required, and shall verify that the CONTRACTOR has provided adequate
heat tracing and insulation during startup activities.
1.8WARRANTY
Extended Equipment Warranty: Refer to Section01 78 36, “Warranties”, for extended
equipment warranty.
All equipment furnished under this section (excluding the carbon media), shall have a special
equipment warranty in accordance with the Contract Documents, for a period of two (2)
years after the date of Substantial Completion of the odor control equipment. The cost of
removal, shipment, repair, and installation by CONTRACTOR shall be included in the
warranty and correction of defective work. Warranty shall include the repair or complete
replacement of the fans, duct work, scrubber vessel, electrical wiring, and controls in the
event of corrosion damage, including equipment, materials, labor, freight, and any and all
costs associated with repairs and replacements (excluding the carbon media).
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PRODUCTS
2.1ACCEPTABLE EQUIPMENT SUPPLIERS
Subject to compliance with the Contract Documents, the following equipment suppliers are
acceptable.
BioAir Technologies
Daniel Mechanical Company
EvoquaWater Technologies
2.2PERFORMANCE AND DESIGN REQUIREMENTS
Source Characteristics
New Broadway Wastewater Treatment Plant:
ThisCarbon AdsorberOdor Control System will treat foul airexhaust from a
biological tower-type odor control system(per Section 44 31 11, “Biological
Tower-Type Odor Control System”). The biological tower-type system will treat
foul air from the Resaca Lift Station wet well. Expected inlet odorant
composition is given in Table 1.
TABLE 1: PERFORMANCE AND DESIGN REQUIREMENTS
Foul Air ParametersValue or Range
Foul Air FlowRate2,700cubic feet per minute (cfm)
Average Inlet Hydrogen Sulfide
2.5ppm
Concentration Range
Inlet Hydrogen Sulfide
15ppm
Concentration Transient Peak
Reduced Sulfides, Mercaptans, Skatoles,
Other Inlet Odorants
Indoles, Amines
Ambient Air Temperature0-
Empty Bed Residence Time (EBRT)3 seconds minimum
Maximum Pressure Drop
6.0 inches w.c., maximum
(from inlet to outlet flanges)
Removal requirements:
Refer to Section 44 31 11, “Biological Tower-Type Odor Control System”, Paragraph
3.3 for additional performance testing requirements.
Remove ninety-nine percent (99%) of inlet hydrogen sulfide based on continuous
datalogger results for inlet concentrations greater than 0.2ppm. For inlet
concentrations less than 0.2 ppm, the outlet concentration shall be less than
0.01 ppm average.
For inlet dilution-to-threshold (D/T) concentration equal to or above 600 D/T, ninety-
percent (90%) odor removalis required; for inlet D/T concentrations below 600,
exhaust D/T concentrations to less than 60 D/T. For influent odors with D/T
concentrations equal to or greater than the laboratory’s maximum value of 60,000,
the sample may be dilutedwith nitrogen gas (per laboratory recommended
procedures)to obtain measurable values.
2.3CARBON ADSORPTION SYSTEM
The EQUIPMENT SUPPLIER shall:
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Supply all materials and equipment exposed to the airstream,orcondensate with
protection from corrosion damage. Corrosion resistant materials and equipment are
required unless specifically permitted in this section.
Provide all hardware, anchors, embedded anchors, and miscellaneous metals that are
Type 316 stainless steel.
Obtain approval from the OWNER or OWNER’s Representative for all coatings to be
used in the completed installation.
Provide sampling ports (minimum 1/2-inch diameter) for the inlet, exhaust andat
least fourintermediate stages to measure airflows and airstream constituents. Ports
will be easily accessible by OWNER’S personnel and will be routed to ground level if a
tower vessel is used. Sample ports routed to ground level shall include a drip leg with
ball valve. Provide a ball valve on the end of the sample line.
All drains from a pressure area will include a trap with cleanout to be provided by
EQUIPMENT SUPPLIER. Trap will contain a depth of water sufficient to prevent
escape of foul air from the system.
Vessel Requirements
All materials used in the vessel will be inherently corrosion resistant or will have a
corrosion resistant coating. Design drawings for vessel(s) shall be sealed by a
licensed engineer registered in the State of Texas.
Acceptable materials include:
Fiberglass Reinforced Plastic (FRP) vinyl ester resin in accordance with ASTM
D3299 and ASME RTP-1.
Provide a gel coat on all surfaces and UV inhibitor on all external
surfaces.
Submit certificate from the vessel manufacturer listing the nomenclature,
composition, and characteristics of the resin, as well as vessel and
support calculations.
Minimum Properties of Resin(s): The 1/8-inch thick unfilled clear casting
strength properties of the resin used will affect the total laminate
strength and service life. The following are minimum acceptable room
temperature (77°F) properties for vinyl ester resin:
PropertyVinyl Ester Resin
Tensile Strength11,000 psi
Tensile Modulus490,000 psi
Elongation5%
Flexural Strength160,000 psi
Flexural Modulus450,000 psi
Heat Distortion Temperature210°F
Barcol Hardness35
Grade 316L stainless steel.
Hastelloy C.
Other materials may be utilized on a case-by-case basis subject to approval by
OWNER and its ENGINEER.
Design Criteria. The carbon absorbervessel should be designed for the criterialisted
in Table 2.
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TABLE 2: CARBON ADSORBER VESSEL DESIGN CRITERIA
ParameterValue
Vessel Diameter(maximum)8 feet
Internal Operating Pressure5.6 in. wc
Maximum Ambient Temperature120°F
Nominal Carbon Bed Depth(minimum)3.0feet
Each unit shall be provided with media support composed of FRP grating and a
polypropylene screen. The grating shall be removable and fully accessible.
Design of the system will be in accordance with applicable local, state, national, and
international standards and codes. Provide an aluminum or FRP ladder with cage and
landings fastened to each adsorberused to access the exhaust stack.
Tank shall meet the following loading criteria:
Wind load limit when anchored:
Ultimate Design Wind Speed; V= 153 mph
ult
Nominal Design Wind Speed; V= 119 mph
asd
Risk Category: III
Exposure: C
Concentrated top load limit: 250 lb. on a 16 square inch area.
Seismic zone: Refer to Drawings for Seismic design requirements.
Media Requirements
Media shall be virgin, pelletized, single-use, bituminous activated carbon,
manufactured in the United States,which will adsorb hydrogen sulfideand other
odorantslisted in Table 1 of this Section.
The mediashall be non-toxic, UL classified, and landfill disposableand shall comply
with the requirements listed in Table 3.
TABLE 3: CARBON MEDIA REQUIREMENTS
ParameterValue
0.39 –0.50
Apparent Density
g/cc
Hardness No. (minimum)95
0.30 g-HS/cc
Hydrogen Sulfide Capacity
Particulate removal: EQUIPMENT SUPPLIER’s design will consider particulates that may be
present in the airstream and will provide for their removal if equipment performance will be
hampered by their presence.
At each discharge stack, provide a replaceable FRP rain cap to protect against moisture
intrusion.
Comply with the requirements of Section09 91 00, “Painting and Protective Coatings.”
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2.4MIST ELIMINATOR
Mist eliminator unit shall consist of a Type 316 stainless steelpad for grease filtration in
front of a polypropylene mesh pad with Type 316stainless steelgrids for mist elimination,
housed inside an FRP enclosure. The pads shall be removable for cleaning and the housing
shall have a drop-out flange to allow removal and replacement of the filter pads. The mist
eliminator pads shall be style 7CA/8P by ACS Industries. The FRP housing shall be flanged
and drilled per PS 15-69 and be ready for installation into the system ductwork.
A Dwyer Series 2000 Magnehilic gauge shall be installed on the housing to indicate pressure
drop through the unit.
2.5ACCESSORIES
Anchor Bolts: Provide template and Type 316 stainless steel anchors and fasteners in
accordance with Section 05 05 23, “Metal Fastenings and Anchor Bolts”, as shown on the
Drawings, and as recommended by the EQUIPMENT SUPPLIER. Size and locations as
required by EQUIPMENT SUPPLIER. EQUIPMENT SUPPLIER shall size all anchor bolts and
fasteners required of ample size and strength for the intended purpose, minimum of ½-inch
diameter. Fastener sizing calculations shall be provided as an informational submittal.
CONTRACTOR shall furnish and install all anchor bolts and fasteners in accordance with the
EQUIPMENT SUPPLIER’s installation instructions.
Equipment Identification Plates: EQUIPMENT SUPPLIER shall furnish a 16-gauge stainless
steel identification plate securely mounted on the equipment in a readily visible location. The
plate shall bear 1/4-inch die-stamped equipment identification number indicated in this
Section and/or on the Drawings.
Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 60
pounds shall be provided with lifting lugs.
Initial Supply of Lubricants: EQUIPMENT SUPPLIER shall indicate types, brands, and
quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants and shall comply with all
EQUIPMENT SUPPLIER recommended procedures.
2.6TOOLS, SPARE PARTS, AND MAINTENANCE MATERIALS
The EQUIPMENT SUPPLIER shall supply one (1) set of spare parts for all components
exposed to operational wear during normal equipment service.
One (1) set of special tools required for maintenance or adjustment.
Two (2) filter pads for mist eliminator.
Other items as recommended by theMANUFACTURER and EQUIPMENT SUPPLIER.
Equipment Lubricants: The EQUIPMENT SUPPLIER shall indicate and verify types, brands,
and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants.
Spare parts shall be packed in sturdy containers with clear, indelible identification markings
and shall be stored in a dry, warm location until transferred to the OWNER at the conclusion
of the project. Each part shall be labeled with part numbers which correspond to the
Operation and Maintenance Data submitted in accordance with Section 01 78 23, “Operation
and Maintenance Data.”
EXECUTION
3.1INSTALLATION
CONTRACTOR to install equipment per this Section and the EQUIPMENT SUPPLIER’s
installation instructions.
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3.2EQUIPMENT SUPPLIER’S SERVICES
EQUIPMENT SUPPLIER Services
EQUIPMENT SUPPLIER Field Representative: The EQUIPMENT SUPPLIER Field
Representative shall be present at the project site or classroom designated by
OWNER for minimum person-days and trips provided in the table below. Each person-
day shall be defined as eight(8) hours duration, exclusive of travel. The EQUIPMENT
SUPPLIER Field Representative shall revisit the jobsite as often as necessary to
correct deficiencies.
TABLE 4: EQUIPMENT SUPPLIER FIELD REPRESENTATIVESERVICES
Work DescriptionNo. Person DaysNo. Trips
Installation assistance and inspection2 1
Functional and performance testing1 Can be combined with installation
Pre-startup classroom or site training1 1
Facility startup2Can be combined with training
Follow up visit 11 months after substantial
1 1
completion for inspection and training
3.3SYSTEM STARTUP
Startup of the facility shall be in accordance with Section 01 75 25, “Equipment Testing and
Startup.” Installation Assistance and Inspection. After Equipment Installation and before
start up, the contractor and EQUIPMENT SUPPLIER Field Representative shall inspect the
installation of the equipment. A preliminary running period (as applicable) will be provided
for the CONTRACTOR to make field adjustments with the EQUIPMENT SUPPLIER Field
Representative. CONTRACTOR shall submit a report for EQUIPMENT SUPPLIER approval of
equipment installation.
Functional Test. CONTRACTOR to start up equipment with EQUIPMENT SUPPLIER Field
Representative. Equipment shall be able to run in manual mode with all associated piping,
electrical and equipment installed to show proper operation of the equipment. Functional
Test shall be 5 days of uninterrupted service. The CONTRACTOR shall be responsible for
equipment operation for the 5-day period. Any delays or additional person days and trips
required for EQUIPMENT SUPPLIER Field Representative to perform Functional Testing
beyond what is specified is the responsibility of the CONTRACTOR. Functional Test can be
run with clean water to demonstrate equipment operation.
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Performance Test and Initial Training. CONTRACTOR and EQUIPMENT SUPPLIER Field
Representative to start up equipment in Automatic Mode (Normal Operation). Equipment
shall run in two modes, normal operation and peak flow conditions. Contractor and
EQUIPMENT SUPPLIER Field Representative should demonstrate any alarms, lead lag
conditions, or total auto mode or other conditions related to equipment operation.
Performance Test shall run with uninterrupted service for 30 days. Performance Test shall
be run with wastewater under normal operating conditions. If equipment fails before 30
days, then theEQUIPMENT SUPPLIER shall correct problems at their own expense and
restart the 30-day Performance Test. EQUIPMENT SUPPLIER and CONTRACTOR are
responsible for equipment operation during the 30-day Performance Test. EQUIPMENT
SUPPLIER shall perform initial training at the end of the 30-day Performance Test for
owner’s representative. Training shall be with a draft of the full Operation and Maintenance
Manuals. Upon completion of Performance Test and Training, The OWNER shall consider
that equipment substantially complete and start the warranty period.
Post-Startup Training. EQUIPMENT SUPPLIER will perform additional training at a time
mutually agreeable to the OWNER and EQUIPMENT SUPPLIER to take place no earlier than
30 days after equipment substantial completion and no later than 90 days after substantial
completion.
3.4GENERAL
Startup of the odor control system will be done in accordance with EQUIPMENT SUPPLIER’s
recommendationsand as specified in Section 01 75 25, “Equipment Testing andStartup.”
Testing of the system will be performed as indicated in Section 44 31 11, “Biological Tower-
Type Odor Control System,” and Section 0073 00, “Supplementary Conditions.”
In the presence of the OWNER and the OWNER’s engineer, CONTRACTOR will test the
operation of the odor control system. Final acceptance will not be made until after
successful completion of the performance testing and receipt of the final installation report.
3.5CLOSEOUT ACTIVITIES
A copy of all information from functional tests including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
END OF SECTION
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SECTION 44 31 83
FOUL AIR COLLECTION SYSTEM TESTING, ADJUSTING, AND BALANCING
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of Contract, Division 1 Specification sections, apply to work
of this section.
B. Related Sections:
1. Section 01 12 16 “Sequence of Construction.”
2. Section 40 05 36.13 “Foul Air Fiberglass Ductwork.”
3. Section 40 05 64.43 “Fiberglass Dampers.”
4. Section 43 11 19 “Foul Air Fans.”
5. Section 44 31 11 “Biological Tower-Type Odor Control System.”
6. Section 44 31 16 “Carbon Adsorber Odor Control System.”
1.2 SUMMARY
A. This Section specifies the requirements and procedures total mechanical systems testing,
adjusting, and balancing. Requirements include measurement and establishment of the fluid
quantities of the mechanical systems as required to meet design specifications and recording
and reporting the results.
B. Contractor shall provide the services of a qualified balancing company to furnish all labor,
materials, equipment, and incidentals to perform the testing, adjusting, and balancing (TAB)
of the modified foul air collection system (FACS) as specified herein and shown on the
Drawings.
C. Test, adjust, and balance the FACS after successful startup and initial operation.
D. This Section does not include:
1. Specifications for materials for patching mechanical systems.
2. Specifications for materials and installation of adjusting and balancing devices. If
devices must be added to achieve proper adjusting and balancing, refer to the
respective system sections for materials and installation requirements.
3. Requirements and procedures for ductwork system leakage tests.
1.3 REFERENCES
A. Definitions
1. Systems testing, adjusting, and balancing is the process of checking and adjusting all
components of the indicated systems to produce the design objectives. It includes:
a. The balance of air distribution.
b. Adjustment of total system to provide design quantities.
c. Electrical measurement.
d. Verification of performance of all equipment and automatic controls.
e. Recording of adjustments, documenting fan speeds, and damper positions.
2. Test: To determine quantitative performance of equipment.
3. Adjust: To regulate the specified air flow rates from the specified treatment units
(e.g., reduce fan speed, throttling).
4. Balance: To proportion flows within the collection/distribution system (sub mains,
branches, and terminals) according to specified design quantities.
5. Procedure: Standardized approach and execution of sequence of work operations to
yield reproducible results.
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6. Report forms: Test data sheets arranged for collecting test data in logical order for
submission and review. These data should also form the permanent record to be
used as the basis for required future testing, adjusting, and balancing.
7. Terminal: The point where the controlled fluid enters or leaves the distribution
system. For this system, terminals are considered to be the section of duct (or fans)
located immediately upstream of the balancing dampers associated with the treatment
units connected to the Foul Air Collection System.
8. Main: Duct or pipe containing the system's major or entire fluid flow.
9. Sub Main: Duct or pipe containing part of the systems' capacity and serving two or
more branch mains.
10. Branch main: Duct or pipe serving two or more terminals.
11. Branch: Duct or pipe serving a single terminal.
B. Related Documents – Comply with the following standards:
1. National Environmental Balancing Bureau (NEBB): Procedural Standards for Testing,
Adjusting, and Balancing of Environmental Systems.
2. American Society of Heating, Refrigeration, and Air Conditioning Engineers, Inc.
(ASHRAE): 2003 ASHRAE Handbook – HVAC Applications, Chapter 37, Testing
Adjusting, and Balancing.
3. Sheet Metals and Air Conditioning Contractors’ National Association (SMACNA): HVAC
Systems – Testing, Adjusting, and Balancing.
1.4 SUBMITTALS
A. Agency Data: Submit proof that the proposed testing, adjusting, and balancing agency
meets the qualifications specified below.
B. Engineer and Technicians Data: Submit proof that the Test and Balance Engineer assigned
to supervise the procedures, and the technicians proposed to perform the procedures meet
the qualifications specified below.
C. Procedures and Agenda: Submit a synopsis of the testing, adjusting, and balancing
procedures and agenda proposed to be used for this Project.
D. Maintenance Data: Submit maintenance and operating data that include how to test,
adjust, and balance the system. At a minimum, record all fan speeds, damper settings,
flows, and pressures required for balancing.
E. Sample Forms: Submit sample forms, if other than those standard forms prepared by the
NEBB are proposed.
F. Certified Reports: Submit testing, adjusting, and balancing reports bearing the seal and
signature of the Test and Balance Engineer. The reports shall be certified proof that the
systems have been tested, adjusted, and balanced in accordance with the referenced
standards; are an accurate representation of how the systems have been installed; are a
true representation of how the systems are operating at the completion of the testing,
adjusting, and balancing procedures; and are an accurate record of all final quantities
measured, to establish normal operating values of the systems. Follow the procedures and
format specified below:
1. Draft reports: Upon completion of testing, adjusting, and balancing procedures,
prepare draft reports on the approved forms. Draft reports may be handwritten, but
must be complete, factual, accurate, and legible. Organize and format draft reports in
the same manner specified for the final reports. Submit two (2) complete sets of
draft reports. Only one (1) complete set of draft reports will be returned.
2. Final Report: Upon verification and approval of draft reports, prepare final reports,
type written, and organized and formatted as specified below. Submit two (2)
complete sets of final reports.
3. Report Format: Report forms shall be those standard forms prepared by the
referenced standard for each respective item and system to be tested, adjusted, and
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balanced. Bind report forms complete with schematic systems diagrams and other
data in reinforced, vinyl, three-ring binders. Provide binding edge labels with the
project identification and a title descriptive of the contents. Divide the contents of the
binder into the below listed divisions, separated by divider tabs:
a. General Information and Summary.
b. Foul Air Fans.
c. Foul Air Collection System Ductwork and Appurtenances.
d. Building HVAC Systems.
G. Report Contents: Provide the following minimum information, forms, and data:
1. General Information and Summary: Inside cover sheet to identify testing, adjusting,
and balancing agency, CONTRACTOR, OWNER, ENGINEER, and Project. Include
addresses, contact names,and telephone numbers. Also include a certification sheet
containing the seal and name address, telephone number, and signature of the
Certified Test and Balance Engineer. Include in this division a listing of the
instrumentations used for the procedures along with the proof of calibration.
2. The remainder of the report shall contain the appropriate forms, including at a
minimum, the information indicated on the standard report forms prepared by NEBB,
for each respective item and system. Prepare a schematic diagram for each item of
equipment and system to accompany each respective report form. Prepare a
schematic diagram for each item of equipment and system to accompany each
respective report form. At a minimum, record all fan speeds, damper settings, flows,
and pressures.
3. A form shall be provided for each measurement taken. At a minimum, measurements
shall be made on each duct branch or main at the following areas:
a. At each air inlet and exhaust for wastewater treatment process units and
structures, as close as feasible to that unit or structure.
b. Before, after, and at each foul air fan.
c. In duct branches and mains before and after each tee, wye, or other connection
where two or more airstreams combine.
d. At other locations sufficient to balance the system to design flows.
4. Provide schematic drawings of the FACS indicating locations of dampers, wyes, tees,
branches, fans, and terminals. Indicate on the schematic drawings the locations
where measurements were made.
H. Calibration Reports: Submit proof that all required instrumentation has been calibrated to
tolerances specified in the referenced standards, within a period of six months prior to
starting the Project.
1.5 QUALITY ASSURANCE
A. Agency Qualifications:
1. Employ the services of an independent testing, adjusting, and balancing agency
meeting the qualifications specified below, to be the single source of responsibility to
test, adjust, and balance the building mechanical systems identified above, so that
design and treatment objectives are reached. Services shall include checking
installations for conformity to design, measurement, and establishment of the fluid
quantities of the mechanical systems as required to meet design specifications and
recording and reporting the results.
2. The independent testing, adjusting, and balancing agency certified by NEBB in those
testing and balancing disciplines required for this project, and having at least one
Professional Engineer registered in the State in which the services are to be
performed, certified by NEBB as a Test and Balance Engineer.
PLUMMER ASSOCIATES, INC. 44 31 83 - PAGE 3 OF 6 BID SET
0537-038-01 FOUL AIR COLLECTION SYSTEM TESTING, ADJUSTING, AND BALANCING JANUARY 2023
B. Pre-Balancing Conference:
1. Prior to beginning of the testing, adjusting, and balancing procedures, schedule and
conduct a conference with the ENGINEER, OWNER, and representatives of installers
of the mechanical systems. The objective of the conference is final coordination and
verification of system operation and readiness for testing, adjusting, and balancing.
1.6 PROJECT CONDITIONS
A. Systems Operation: Systems shall be fully operational prior to beginning procedures.
PART 2 - PRODUCTS
2.1 MISCELLANEOUS
A. As part of the balancing service, CONTRACTOR shall install additional sheaves as required in
order to make adjustments to fans to achieve design air flows and pressures. Sheaves
would be purchased by the OWNER and installed by the CONTRACTOR.
B. Sheaves shall be new and shall be of the type and material as recommended by the
manufacturer of the fan. Adjustable sheaves are not acceptable.
PART 3 - EXECUTION
3.1 PRELIMINARY PROCEDURES FOR AIR SYSTEM BALANCING
A. Before operating the system, perform these steps:
1. Obtain design drawings and specifications and become thoroughly acquainted with
the design intent.
2. Obtain copies of approved shop drawings of all new and existing air handling
equipment that is part of the Foul Air Collection System.
3. Compare design to installed equipment and field installations.
4. Walk the system from the system air handling equipment to terminal units to
determine variations of installation from design.
5. Check filters for cleanliness.
6. Check dampers for correct and locked position for completeness of installation before
starting fans.
7. Prepare report test sheets for both fans and affected treatment units. Prepare a
summation of required treatment unit ventilation volumes to permit a crosscheck with
required fan volumes.
8. Determine best locations in main and branch ductwork for most accurate duct
traverses.
9. Place balance dampers in the full open position.
10. Prepare schematic diagrams of system "as-built" ductwork and piping layouts to
facilitate reporting.
11. Lubricate all motors and bearings.
12. Check fan belt tension.
13. Check fan rotation.
3.2 MEASUREMENTS
A. Provide all required instrumentation to obtain proper measurements, calibrated to the
tolerances specified in the referenced standards. Instruments shall be properly maintained
and protected against damage.
B. Provide instruments meeting the specifications of the referenced standards.
PLUMMER ASSOCIATES, INC. 44 31 83 - PAGE 4 OF 6 BID SET
0537-038-01 FOUL AIR COLLECTION SYSTEM TESTING, ADJUSTING, AND BALANCING JANUARY 2023
C. Use only those instruments which have the maximum field measuring accuracy and are best
suited to the function being measured.
D. Apply instruments as recommended by the manufacturer.
E. Use instruments with minimum scale and maximum subdivisions and with scale ranges
proper for the value being measured.
F. When averaging values, take a sufficient quantity of readings which will result in a
repeatability error of less than 5 percent. When measuring a single point, repeat readings
until 2 consecutive identical values are obtained (plus or minus 2 percent).
G. Take all reading with the eye at the level of the indicated value to prevent parallax.
H. Use pulsation dampeners where necessary to eliminate error involved in estimating average
of rapidly fluctuation readings.
I. Take measurements in the system where best suited to the task.
3.3 PERFORMING TESTING, ADJUSTING, AND BALANCING
A. Perform testing and balancing procedures on each system identified, in accordance with the
detailed procedures outlined in the referenced standards.
B. Cut insulation on ductwork or piping for installation of test probes to the minimum extent
necessary to allow adequate performance of procedures.
C. Patch insulation, ductwork, and housings, using materials identical to those removed.
D. Seal ducts and piping and test for and repair leaks.
E. Seal insulation to re-establish integrity of the vapor barrier.
F. Mark equipment settings, including concealed damper control locations, fan speed control
levers, and similar controls and devices, to show final settings. Mark with paint or other
suitable, permanent identification materials.
G. Retest, adjust, and balance systems subsequent to significant system modifications, and
resubmit test results.
H. If required, change sheaves of fans with suitable size in order to properly balance system.
Turn over all belts and sheaves removed from the blowers to the Owner.
3.4 RECORD AND REPORT DATA
A. Record all data obtained during testing, adjusting, and balancing in accordance with, and on
the forms recommended by the referenced standards, and as approved on the sample
report forms. Particular emphasis should be given to recording damper positions within 5
percent, fan speeds, and pressures at fans and processes. Identify specific locations where
measurements were made.
B. Prepare report of recommendations for correcting unsatisfactory mechanical performances
when system cannot be successfully balanced.
3.5 DEMONSTRATION
A. Training:
1. Train the OWNER's maintenance personnel on troubleshooting procedures and
testing, adjusting, and balancing procedures.
2. Schedule training with Owner through the Engineer with at least 7 days prior notice.
END OF SECTION
PLUMMER ASSOCIATES, INC. 44 31 83 - PAGE 5 OF 6 BID SET
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SECTION 46 21 83
SEPTAGE RECEIVING STATION
PART 1 - GENERAL
1.1 SUMMARY
A. This section of the specification describes the septage receiving station and controller. The
equipment shall be installed as shown on the plans, as recommended by the supplier, and in
compliance with all OSHA, local, state and federal codes and regulations. The equipment to
be provided shall include:
1. One (1) electrically actuated plug valve
2. One (1) rock trap
3. One (1) grinder
4. One (1) inline flow meter
5. One (1) level indicator inside the screening and compactor tank
6. One (1) enclosed screening and compactor unit with spray-wash system
7. Inlet piping and bends, outlet connection, and wash water connection(s)
8. One (1) control panel with relevant electrical controls
9. One (1) station access panel with relevant electrical controls
1.2 REFERENCES
A. Station shall, as applicable, meet the requirements of the applicable ASTM, ANSI, and AISI
standards.
B. Controllers shall, as applicable, meet the requirements of NEMA, NEC, UL and cUL, and IEC.
C. Related Sections:
1. Section 09 91 00 “Painting and Protective Coatings”
2. Section 40 05 62 “Plug Valves”
3. Section 40 05 23 “Stainless Steel Process Pipe and Tubing”
4. Section 40 61 00, “Process Control and Instrumentation Systems - General Provisions”
5. Section 40 63 00, “PLC Hardware and Software”
6. Section 40 66 00, “Network Equipment”
7. Section 43 22 10 “Common Requirements for Pumps”
1.3 ADMINISTRATIVE REQUIREMENTS (NOT USED)
1.4 SUBMITTALS
A. Copies of materials required to establish compliance with the specifications shall be
submitted in accordance with the provisions of Section 01 33 00, “Submittal Procedures”.
B. Submittals shall include at least the following:
1. MANUFACTURER shall provide a copy of this Section and indicate for each specification
item in this Section that the requirement is acknowledged. All deviations from the
contract documents shall be clearly identified in a separate list.
2. Certified shop and erection drawings showing all important details of construction,
dimensions, anchor bolt size and locations, and field connections.
3. Descriptive literature, bulletins, catalogs, and cutsheets of the equipment.
4. Total weight of the equipment including the weight of each component included.
5. A complete bill of materials for all equipment.
6. Nearest location of factory maintenance and service facilities that will be available to
service the equipment offered.
7. Complete warranty information.
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0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
8. Auxiliary Instrumentation and Devices:
a. Datasheets and mounting locations/details for auxiliary instrumentation and
devices furnished with equipment. The information shall include associated
mounting brackets and hardware.
9. Wiring Diagrams:
a. For power, signal, and control wiring diagrams, including terminals and
numbers.
10. Test Reports:
a. Supplied per this specification.
C. Informational Submittals
1. Field Representative Resume
2. Qualifications Statement
3. Previous Installations List
4. Pre-Installation Delivery, Storage, and Handling Instructions
5. Installation Instructions
6. Fastener and Support Sizing Calculations
D. Closeout Submittals
1. Paint
2. Spare Parts
3. Operation and Maintenance Data
4. Warranty Documentation
5. Testing Data
1.5 QUALITY ASSURANCE
A. Identification:
1. Equipment nameplates shall be provided for the screen and compactor system as well
as each motor supplied. Nameplates shall be Type 316 Stainless Steel and affixed in a
conspicuous location.
2. Nameplate information shall include MANUFACTURER’s name and address, equipment
3. model number, and serial number for the screen and compactor system. For each
motor, the MANUFACTURER’S name and address, equipment model and serial number,
and pertinent motor information shall be provided.
B. MANUFACTURER:
1. A named MANUFACTURER does not constitute owner acceptance of an alternate
product. The submitted product must meet the functional and specific requirements of
the construction plans, this specification section and referenced specification sections.
2. SUPPLIER shall have a minimum of ten (10) prior installations of similar equipment.
3. SUPPLIER shall provide a list of reference sites for similar equipment for verification by
4. the ENGINEER or OWNER’s Representative.
5. SUPPLIER shall conduct factory testing and verification of equipment prior to shipment.
C. Installation & Start-up:
1. SUPPLIER shall provide services of a factory trained representative to check installation
and review start-up of equipment and controls.
2. SUPPLIER Representative shall inspect and approve site installation and supervise a
review of the operation of the equipment.
3. SUPPLIER Representative shall provide training on operation and maintenance
requirements of the equipment.
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 2 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver, handle and store septage receiving station system components in accordance with
manufacturer’s written instructions and the requirements of Section 01 60 00 “Product
Requirements”.
1.7 SITE CONDITIONS
A. The equipment, sizes, materials, and arrangements described in this section are based on
recommendations by equipment suppliers and shall be considered minimum limits of
acceptability. The CONTRACTOR shall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
B. Environmental Conditions:
1. All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
2. The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases encountered in municipal wastewater treatment plants.
3. Ambient chloride levels will be elevated due to the proximity to seawater.
4. All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 110°F.
5. Furnish heat tracing and insulation as required. Insulation alone shall not be sufficient
to fulfill freeze protection provisions of this section.
1.8 WARRANTY
A. Extended Equipment Warranty: Refer to Specification 01 78 36 “Warranties” for extended
equipment warranty.
B. All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years from the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
C. Manufacturer shall provide labor on-site to diagnose and correct any problem that is not
resolved via telephone communication with plant personnel within 72 hours or that reoccurs
during this warranty period.
D. Manufacturer shall provide a factory field representative within two weeks of problem
occurrence, for non-emergency repairs. Cost for the removal, shipment, repair and
installation by CONTRACTOR shall be included in warranty, as well as correction of defective
work.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. The following named MANUFACTURERs are recognized suppliers of Septage Receiving
Stations and may be incorporated into the work. No other MANUFACTURERs are allowed.
1. Saveco (formally Enviro-Care)
2. Franklin-Miller
3. Huber Technology
4. Hydro-Dyne
5. JWC Environmental
6. Lakeside Equipment Corporation
7. SCG Metcon
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 3 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
2.2 SEPTAGE RECEIVING SYSTEM OVERVIEW
A. General:
1. The Septage Receiving Station shall provide pre-authorized users a means to access
and unload trucked-in waste at the New Broadway Wastewater Treatment Plant.
2. The station will identify and validate the waste hauler and prompt for entry of manifest
information.
3. The station will automatically operate an inlet valve, record the transaction data for
billing, and measure the flow rate of the waste.
4. The rock trap and/or grinder may not be required for all MANUFACTURERs. If these
components are not required, MANUFACTURER shall submit a signed letter per
Paragraph 1.4.B.1 of this Section.
B. Performance:
a. Septage receiving station shall be rated for 400 GPM of septage flow and a 15
PSI maximum inlet pressure.
b. Station shall have a minimum of 2,000 gpm clear liquid hydraulic capacity.
2.3 MECHANICAL COMPONENTS
A. Inlet Piping and Connections:
1. Overview:
a. Inlet piping shall provide connections between inlet, rock trap, grinder, plug
valve, flow meter, and screening and compactor unit.
2. Components:
a. Inlet Piping shall be constructed of passivated AISI 316 stainless steel per
Section 40 05 23 “Stainless Steel Process Pipe and Tubing”.
b. Pipe segments shall have 4-inch class 150 lb weld neck flanges.
c. Gaskets shall be constructed of 1/8 neoprene rubber.
d. Fasteners, pipe supports, and all other accessories shall be constructed of Type
316 Stainless Steel.
3. CONTRACTOR shall provide all interconnecting piping as required for the
MANUFACTURER’s system.
B. Plug Valve:
1. Overview:
a. The electrically actuated plug valve shall provide security and regulate the
process flow. Refer to Section 40 05 62 “Plug Valves.”
b. During normal operation, the plug valve shall be controlled via the control
panel and programmable logic control (PLC) programming.
2. Components:
a. Actuator:
1) Electric and pneumatic operators and actuators shall comply with the
2) requirements of the Section 40 05 57.23, “Electric Motor Actuators”.
3) The actuator enclosure shall be NEMA 4X rated.
4) The actuator shall have a drive hand wheel for emergency manual
operation.
C. Rock Trap:
1. Overview:
a. Rock trap shall reduce inlet velocities to allow large objects entrained in the
process flow to be captured and removed at a convenient location.
b. A manual knife gate shall allow the captured objects to be discharged into a
debris receptacle for draining of excess liquid and disposal of the large objects.
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 4 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
2. Components:
a. Rock trap shall be constructed of ductile iron.
b. The rock trap shall have 4-inch inlet and outlet connections and be capable of
collecting particles 1/2-inch in diameter and larger.
c. Rock trap shall be coated per the requirements in Section 09 91 00, “Painting
and Protective Coatings”.
D. Flow Meter:
1. Overview:
a. The inline flow meter shall monitor the flow rate of the influent waste and
transmit data to the controller.
b. If the flow rate is less than or equal to 400 gpm, the controller will allow the
plug valve to open and the waste to be discharged to the screening unit.
Alternatively, a level sensor in the tank may be used to control the opening and
closing of the plug valve.
2. Components:
a. The flow meter shall be capable of severe-duty applications typical in influent
wastewater applications.
b. The flow meter shall measure the process liquid with a range of 0 – 500 gpm.
c. The flow meter shall be mounted on a pipe segment that will have 4-inch class
150lb weld neck-flanges.
d. Pipe segment shall be constructed of passivated AISI 316 stainless steel.
E. Grinder:
1. Overview:
a. Grinder shall be provided downstream of the rock trap to reduce the size of any
large particles before entering the screen and compactor.
b. Depending on the MANUFACTURER selected, the rock trap may be
incorporated into the grinder.
2. Components:
a. Grinder shall be provided per the Schedule at the end of this Section.
b. Grinder shall have pushbuttons or a selector switch to enable ON/OFF/AUTO
operation.
1) ON shall turn the grinder on.
2) OFF shall turn the grinder off.
3) AUTO shall allow the pump to operate via the control panel.
c. Coating:
1) Provide polyurethane, pigmented (over epoxy zinc rich primer and high
build epoxy) in accordance with Section 09 91 00 “Painting and Protective
Coatings.” Pump shall receive surface preparation, prime coat and finish
coat in factory.
2) Shop painted items which suffered damage to the shop coating shall be
touched up as specified in Section 09 91 00 “Painting and Protective
Coatings.”
F. Screening Unit:
1. Overview:
a. Screening unit shall be provided in a completely enclosed Type 316 Stainless
Steel tank. Screen shall act as preliminary treatment before the septage flows
to the influent lift station.
b. Septage influent water and particles less than the screen perforations shall pass
to the lower tank level and exit the unit via the outlet pipe. Septage particles
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 5 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
greater than the screen perforations shall be retained and pass to the
compactor, which is described below.
2. Components:
a. Screen:
1) Screen shall be either a perforated plate rotating drum type screen with a
rotating screen basket or a perforated plate type screen. Perforations shall
be around the entire circumference of the screen.
2) Screen openings shall be no larger than 0.25” in diameter.
b. Cleaning Brush:
1) An integral cleaning brush shall be provided to clean the drum
perforations. Brush shall be mounted on a Type 316 Stainless Steel shaft
on the outside of the drum screen or auger flight and maintain contain
with the screen during rotation.
a) All mounting hardware and bearings shall be Type 316 Stainless
Steel.
b) All bearings shall be permanently lubricated.
2) Spray wash system may be used in lieu of a cleaning brush.
MANUFACTURER shall submit a signed letter stating the cleaning brush is
not required and describe the system used to clean the screen.
c. If integral to the function of the unit, a level sensor may be provided by the
MANUFACTURER. Sensor shall be suitable for operation in corrosive septage
conditions.
d. All screening equipment and hardware shall Type 316 Stainless Steel.
e. Inlet shall be designed limit sedimentation in the tank.
f. Screen motor shall be provided per the MANUFACTURER’s requirements and
shall be TEFC.
1) Motor shall have pushbuttons or a selector switch to enable ON/OFF/AUTO
operation.
a) ON shall turn the motor on.
b) OFF shall turn the motor off.
c) AUTO shall allow the screen to operate via the control panel.
2) In lieu of a separate screen motor, a single motor for the screen and
compactor may be provided. If a single motor is provided,
MANUFACTURER shall provide signed letter stating the unit only requires
one motor and the single motor will not negatively impact performance.
g. Coating:
1) Provide coating in accordance with Section 09 91 00 “Painting and
Protective Coatings.” Pump shall receive surface preparation, prime coat,
and finish coat in factory.
2) Shop painted items which suffered damage to the shop coating shall be
touched up as specified in Section 09 91 00 “Painting and Protective
Coatings.”
G. Compactor:
1. Overview (Alternative 1):
a. Solids retained on the screening unit shall pass to the screw compactor. The
compactor shall be connected to the screen.
b. Solids shall be transported up at an angle through an encased screw compactor
or auger to promote dewatering. Excess water shall fall through perforated
openings and drain to the lower screening tank and be discharged.
c. Solids shall be discharged to a dumpster provided by the CONTRACTOR.
5
2. Overview (Alternative 2):
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 6 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
a. Solids retained on the screening unit shall be transported to the compaction
zone via an auger at an angle.
b. The compaction zone shall consist of a tube. As more solids are conveyed to
the compaction zone, pressure builds, dewatering and compacting the solids,
and allowing water to drain through perforations at the base of the tube. The
compacted solids shall be discharged. A cutter shall be included to facilitate
discharge as needed, and a spray system shall be included to clean the
compaction zone tube.
c. Solids shall be discharged to a dumpster provided by the CONTRACTOR.
5
3. Components:
a. Screw or Auger Compactor (Alternative 1):
1) All materials shall be Type 316 Stainless Steel.
2) Compactor shall be encased in a Type 316 Stainless Steel tube.
3) Compactor shall be angled to promote maximum dewatering and drainage
of excess water.
b. Auger (Alternative 2):
1) All materials shall be Type 316 Stainless Steel.
2) Auger shall be encased in a Type 316 Stainless Steel tube.
3) Auger shall be angled to promote maximum dewatering and drainage of
excess water.
c. Compaction Zone (Alternative 2):
1) All materials shall be Type 316 Stainless Steel.
d. Compactor motor shall be provided per the MANUFACTURER’s requirements
and shall be TEFC.
1) Motor shall have pushbuttons or a selector switch to enable ON/OFF/AUTO
operation.
a) ON shall turn the motor on.
b) OFF shall turn the motor off.
c) AUTO shall allow the pump to operate via the control panel.
2) In lieu of a separate compactor motor, a single motor for the compactor
and screen may be provided. If a single motor is provided,
MANUFACTURER shall provide signed letter stating the unit only requires
one motor and the single motor will not negatively impact performance.
e. Coating:
1) Provide coating in accordance with Section 09 91 00 “Painting and
Protective Coatings.” Pump shall receive surface preparation, prime coat,
and finish coat in factory.
2) Shop painted items which suffered damage to the shop coating shall be
touched up as specified in Section 09 91 00 “Painting and Protective
Coatings.”
f. All other fasteners and accessories shall be Type 316 Stainless Steel.
g. A 316 Stainless Steel hinged cover shall be provided to inspect the compactor
as needed.
h. Provide½" thick rubber tubular discharge chute that connects to the discharge
and extends down to the dumpster.
5
H. Spray Wash System:
1. Overview:
a. Spray washing systems are required for the screen and compactor to keep
these items clean and prevent sludge build up. MANUFACTURER is responsible
for providing a complete spray washing system.
2. Components:
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 7 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
a. All tubing inside the enclosed unit shall be Type 316 Stainless Steel and shall
be provided per Section 40 05 23 “Stainless Steel Process Pipe and Tubing”.
b. For each connection, there shall be a flow control valve provided by the
MANUFACTURER to regulate wash water flow as needed.
c. See the Schedule at the end of this Section for connection and plant water
requirements.
2.4 CONTROL PANEL
A. A dual enclosure controller shall provide control of the septage receiving station
components. The operator enclosure shall have a magnetic card reader, Operator Interface
Terminal, printer, and control devices for operating the system and providing data collection.
The main enclosure shall have indicator lights, switches, and other control devices.
B. Components:
1. Enclosures
a. Main enclosure shall be AISI 316 stainless steel NEMA 4X and house the control
devices, motor starters, Emergency Stop and PLC.
Operator Enclosure shall be AISI 316 stainless steel NEMA 4X with attached
devices to include receipt printer, magnetic card reader, 5.7” industrial monitor
and keypad and micro-PC.
2. Magnetic Card Reader (OperatorEnclosure)
a. Card reader shall be rated for outdoor and coastal environment use.
b. Card reader shall provide identification and authorization for use of the system.
3. Printer (Operator Enclosure)
a. Printer shall use a minimum of 60 mm wide single roll thermal paper.
b. Printer shall print a transaction receipt that lists site address, date, time, and
user ID.
4. Operator Interface Terminal (Operator Enclosure)
a. OIT shall be rated for outdoor and coastal environment use or protected for
outdoor and coastal environment use.
b. OIT shall display fail, service reminder and operational messages.
c. OIT shall include a 2GB minimum SD Card for data backup and transfer. Data
shall be stored and formatted in .csv files.
d. OIT shall have color display, Ethernet port, USB ports and flash card port.
5. Micro PC (Operator Enclosure)
a. MPC shall communicate with the administrative office software all relative data
associated with operating the station, including data to validate user access,
unloaded volumes, flow reading, and alarms. Communication shall be via
Ethernet I/P, PROFINET, or Modbus TCP.
b. MPC will have an internal static hard-drive and memory or SD memory card to
store 100,000 records of backup data.
6. Start & Stop Pushbuttons (Operator Enclosure)
a. Pushbuttons shall be rated NEMA 4X.
b. Start push button shall initiate operation of the system after successful
identification and authorization of the user’s PIN has been entered via the card
reader or OIT.
c. Stop pushbutton shall initiate a stop of the system and immediately close the
plug valve. Transaction data shall be written to the PLC data register and a
transaction receipt printed.
7. Plug Valve OPEN/CLOSE/AUTO three-position keyed selector switch. (Main Enclosure)
a. In the OPEN position, the plug valve will open.
b. In the CLOSE position, the plug valve will close.
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c. In the AUTO position, the plug valve will open and close as controlled by the
PLC programming.
8. Grinder ON/OFF/AUTO three-position keyed selector switch. (Main Enclosure)
a. In the ON position, the grinder pump shall be turned on.
b. In the OFF position, the grinder pump shall be turned off.
c. In the AUTO position, the grinder pump shall be operated per the PLC
programming.
9. Drum Screen Motor ON/OFF/AUTO three-position keyed selector switch. (Main
Enclosure)
a. In the ON position, the motor shall be turned on.
b. In the OFF position, the motor shall be turned off.
c. In the AUTO position, the motor shall be operated per the PLC programming.
10. Compactor Motor ON/OFF/AUTO three-position keyed selector switch. (Main Enclosure)
a. In the ON position, the motor shall be turned on.
b. In the OFF position, the motor shall be turned off.
c. In the AUTO position, the motor shall be operated per the PLC programming.
11. MANUFACTURER may provide a single motor for the screen and compactor.
a. If a single motor is provided, MANUFACTURER shall provide a signed letter
stating separate motors are not needed, and the single motor will not
negatively affect the unit’s operation.
b. The single motor shall have the same components and features as listed for the
screen and compactor motor.
12. Flow meter indicator (Main Enclosure)
a. Flow meter indicator shall provide the flow rate in gallons per minute (gpm).
13. Level sensor indicator (Main Enclosure)
a. Level sensor indicator shall record the level in the enclosed tank.
b. An alarm condition shall occur if the level in the tank exceeds the high-water
level in the PLC programming, operation shall immediately cease, and only
resume when the tank level is below the high-water level.
14. RESET momentary two-position keyed selector switch. (Main Enclosure)
a. Switch shall be rated NEMA 4X
b. Reset switch shall clear any fault condition and rest system for operation.
15. Pilot Lights (Main Enclosure)
a. Lights shall be LED type rated NEMA 4X.
b. Lights shall indicate PLUG VALVE OPEN and FAIL.
16. Emergency Stop Pushbutton (Main Enclosure)
a. Emergency Stop Pushbutton shall be rated NEMA 4X.
b. When activated, Emergency Stop shall close plug valve and de-energize
solenoid valves.
C. Safety Features
1. When a power failure occurs while the system is operating, the transaction shall
terminate. Once power is restored, a receipt shall print.
2. Reset shall only be from the main control only.
2.5 SPARE PARTS
A. The following spare parts shall be provided:
1. Five (5) spare spray nozzles for the wash water system.
2. One (1) solenoid valve rebuild kit if the solenoid valves are used for the wash water
system. If ball valves are provided, this item is not required.
PLUMMER ASSOCIATES, INC. 46 21 83 - Page 9 of 10 BID SET
0537-038-01 SEPTAGE RECEIVING STATION JANUARY 2023
3. One (1) drum/inner HDPE seal if used by the MANUFACTURER.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Septage Receiving Station and control panel shall be installed in accordance with the
SUPPLIER’s installation instructions, and in accordance with all OSHA, local, state, and
federal codes and regulations.
3.2 START-UP AND TESTING
A. MANUFACTURER shall provided one (1) qualified representative for a maximum of two (2)
eight (8) hour days.
B. MANUFACTURER’s representative shall inspect the unit and assist in installation as required.
C. MANUFACTURER’s representative shall test the Septage Receiving Station to demonstrate
correct alignment, smooth operation and freedom of excessive vibration and noise. Test
period shall include one cycle of processed septage that demonstrates accurate
measurement of the flow and all run cycles are properly set.
3.3 TRAINING
A. The MANUFACTURER’s representative shall conduct a field training course for operating and
supervisory staff members. Field instruction shall cover all items contained in the operation
& maintenance manuals.
END OF SECTION
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F:\\PROJECTS\\0537\\038-01\\9 DESIGN\\9-4 SPECIFICATIONS\\CONFORMED\\46 21 83 SEPTAGE RECEIVING STATION.DOCX
SECTION 46 23 63
GRITCLASSIFYING AND WASHING EQUIPMENT
GENERAL
1.1SUMMARY
Provide two grit classifiers. The classifiers shall connect to the existing grit removal systems.
The classifiers’ discharge shall be collected and conveyed to the existing dumpster system.
Furnish, install, startup, and test grit classifier units,complete and operational with all
necessary controls and connections, including a control panel.
The EQUIPMENT SUPPLIER shall furnish, install, startup and test the grit system train
control panels, that monitor and control vortex-type grit removal mechanisms, grit pumps,
girt classifier and washing system and solenoid and fluidization valves for complete and
operational system. Panels to include required starters, breakers, control power transformers
and PLCs as shown on the Plans and as specified herein. Panel installation by the
CONTRACTOR. EQUIPMENT SUPPLIER shall coordinate with CONTRACTOR on required
control connections.
1.2REFERENCES
Drawings and general provisions of the Contractapply to this section.
American Bearing Manufacturer’s Association (ABMA):
9 –Load Ratings and Fatigue Life for Ball Bearings
11 –Load Ratings and Fatigue Life for Roller Bearings
National Fire Protection Association (NFPA): NFPA 70, National Electric Code.
Related Sections:
Section 40 05 51 “Common Requirements for Process Valves”
Section 40 05 93 “Common Motor Requirements for Process Equipment”
Section 40 05 91 “Common Control Panel Requirements for Process Equipment”
1.3ADMINISTRATIVE REQUIREMENTS –NOT USED
1.4SUBMITTALS
Action Submittals
MANUFACTURER shall provide a copy of this Section and indicate for each
specification item in this Section that the requirement is acknowledged. All deviations
from the contract documents shall be clearly identified in a separate list.
Product Data: Provide construction details, material descriptions, dimensions of
individual components and profiles, rated capacities, operating characteristics,
electrical characteristics, and furnished specialties and accessories.
Shop Drawings:
Shop drawings specific to project and applicable product data bound neatly in a
single package. The following information shall be included as a minimum:
Manufacturernameand model number of equipment.
Layout drawings including all proposed system components with loads,
method of field assembly, dimensions, clearances required withsizes
indicated, and arrangement and size of connections.
Listing of materials of construction, details of construction, specifications
and data for all components and coatings information.
Layout, size, type and material for anchor bolts to be furnished.
Color selection charts for coatings.
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Motors:
Complete submittal per Section 40 05 93 “Common Motor
Requirements for Process Equipment”.
Auxiliary Instrumentation and Devices: Datasheets and mounting
locations/details for auxiliary instrumentation and devices furnished with
equipment. The informationshall include associated mounting brackets
and hardware.
Wiring Diagrams: If applicable, for power, signal, and control wiring
diagrams, including terminals and numbers.
Equipment performance curves.
Equipment weights and lifting points.
Warranties and service agreements.
List of similar installations including names and telephone numbers of contacts.
Information Submittals:
Field Representative Resume
Qualifications Statement
Previous Installations List
Pre-Installation, Special Shipping, Delivery, Storageand Protection, and Handling
Instructions
Manufacturer’s instructions for installation.
Recommended Equipment Lubricants
Samples
Certificates
Software
Manufacturer’s Certification of Compliance.
Manufacturer’s Certificate of Proper Installation.
Location and contact information of nearest stocking distributor of spare parts.
Suggested spare parts list to maintain the equipment in service for a period of one
year. Include a list of special tools required for checking, testing, parts replacement,
and maintenance,with current pricing information.
Coordination Drawings: Grit separation, concentration and dewatering system;
consisting of grit cyclones, grit dewatering, control panels and instrumentation, and
other details, drawn to scale, on which all components of the grit system are shown
and coordinated with each other.
Welding certificates.
Startup and test schedule.
Source quality-control reports.
Field quality-control reports.
Closeout Submittals
Paint
Lubricants
Spare Parts
Operation and Maintenance Data
Warranty Documentation
Record Data Documentation
Extra Stock Materials
Tools and Software
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1.5QUALITY ASSURANCE
All equipment of each type specified in this section shall be supplied by a single EQUIPMENT
SUPPLIER who is fully experienced, reputable and qualified in the manufacture of the
equipment to be furnished. The equipment shall be designed, constructed, and installed in
accordance with the best practices and methods.
Field Representative: The EQUIPMENT SUPPLIER shall furnish a qualified field representative
for the time indicated in Paragraph 3.5.A of this Section. Field representatives shall be
factory-employed personnel and have a minimum of two (2) years of experience with the
operation of and training on this type of equipment. Sales representatives will only be
considered acceptable service technicians if they have three (3) years of experience with the
operation of and training on this type of equipment from the EQUIPMENT SUPPLIER being
supplied and have started up 15 units of a similar size and type from the EQUIPMENT
SUPPLIER. The field representative shall submit a resume for approval before startup
assistance can be provided. For each training event two separate pre-startup training
sessions shall be performed, one in the early morning and one in the late afternoon.Two
separate post-startup training sessions shall be performed, one in the early morning and one
in the late afternoon. CONTRACTOR shall coordinate the scheduling of such training and
startup assistance with OWNER’S personnel. A typed outline shall be handed out at each
training session and, at a minimum, will include normal operating parameters, alarms, and
maintenance.
EQUIPMENT SUPPLIER shall maintain a complete stock of spare parts commonly needed for
the equipment specified at a location within the State of Texas, or shall be capable of
furnishing spare parts within forty-eight (48) hours of request.
Qualifications: Equipment shall be the product of an EQUIPMENT SUPPLIER having at least
twenty (20) similar system installations experience in the United States of the type
proposed, each with a minimum of five (5) years of satisfactory service.
Previous Installations List: A list of similar installations demonstrating the experience
requirement shall be furnished. List shall include EQUIPMENT SUPPLIER name. Each
installation shall include project State, project City, project name, project date, equipment
model number, client name(s), and client phone number(s).
EQUIPMENT SUPPLIER shall furnish all equipment with a 316 stainless steel nameplate
securely affixed in a conspicuous place on the equipment showing the equipment ratings,
serial number, model number, equipment supplier name, and other pertinent nameplate
data.
Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA70,
by a qualified testing agency, and marked for intended location and application.
1.6DELIVERY, STORAGE, AND HANDLING
Deliver, handle, and store all components to be installed under this section in accordance
with the EQUIPMENT SUPPLIER’S written Pre-Installation Delivery, Storage, and Handling
Instructions and the requirements of Section 01 60 00 “Product Requirements.”
Motors shall be stored as indicated in Section 40 05 93 “Common Motor Requirements for
Process Equipment”.
1.7SITE CONDITIONS
The equipment, sizes, materials, and arrangements described in this section are based on
recommendations by equipment suppliers and shall be considered minimum limits of
acceptability. The EQUIPMENT SUPPLIER shall be responsible for design, arrangement, and
performance of all equipment supplied under this section.
Environmental Conditions:
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All equipment including controls and drives specified herein shall be specifically
designed to be installed for this service and the environment encountered in this
installation, unless noted otherwise.
The environment will be moist, and corrosive, exhibiting hydrogen sulfide and other
corrosive gases as well as elevated chloride levels encountered in municipal
wastewater treatment plantsand coastal environments.
All equipment shall be designed and capable of operation outdoors at ambient
temperatures of 10°F to 110°F.
Equipment shall be compatible with heat tracing and insulation, which will be
furnished and installed by the CONTRACTOR. EQUIPMENT SUPPLIER shall design
piping systems with ample clearances and material compatibility to accept required
heat tracing and insulation. If additional freeze protection beyond heat tracing and
insulation is required it shall be furnished by the EQUIPMENT SUPPLIER. EQUIPMENT
SUPPLIER shall coordinate with the CONTRACTOR to provide direction on where heat
tracing is required, and shall verify that the CONTRACTOR has provided adequate
heat tracing and insulation during startup activities.
1.8WARRANTY
Extended Equipment Warranty: Refer to Section01 78 36 “Warranties” for extended
equipment warranty.
All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of two (2) years after the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
PRODUCTS
2.1ACCEPTABLE EQUIPMENT SUPPLIERS
Subject to compliance with the Contract Documents, the following equipment suppliersare
acceptable.
WEMCO Hydrogritter
Smith & Loveless, Inc.
Ovivo/Jones & Attwood, Ltd.
No like, equivalent, nor “or-equal” item or substitution is permitted.
2.2CYCLONE GRIT CONCENTRATOR
Unit Description:
Cyclone shall have an involuted feed entry with a minimum inlet and outlet size as
specifiedin Table 2after the “END OF SECTION”and adapter pieces to fit the piping
layout shown on the Drawings.A tangential feed entry is permissible as long as the
system has a means for energy dissipation. MANUFACTURER shall provide
documentation justifying a tangential feed entry, if applicable.
Cyclone shall be complete with inlet head cylinder, upper cone section, replaceable
Neoprene or Ni-hard liner, 500 BHN minimum vortex head cylinder, inlet pressure
gage, and diaphragm assembly.
Underflow from cyclone shall discharge into a screw type grit classifierfor washing
and dewatering, and be sized so that the proper hydraulic loading is provided to the
classifier.
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The cyclone overflow will feed to piping furnished by the contractor which must be
properly and adequately vented per the manufacturer’s drawings to prevent
siphoning.
Cyclone shall be mounted on the grit classifier unitat a maximum incline of 45
degrees.It shall be provided with flange connections meeting 150 lb. ASA steel flange
standards.
The cyclone manufacturer shall supply a fabricated 316 stainless steel support to
mount the cyclone.
The cyclone shall be attached to a 3/8 inch 316 stainless steel mounting plate,
designed such that the cyclone is properly oriented into the classifier
feedboxes.
The cyclone mounting plate shall be independently supported with two
structural steel supports, designed for attachment to the floor with anchor
bolts.
Operation Description:
Cyclone grit concentratorsupplied shall operate by vortex principle of a design such
that a small amount of water will discharge at the bottom with a concentrated volume
of grit. The larger volume of water shall flow out the top and be returned ahead of
the grit chamber. Each unit shall be capable of intermittent operation and maintain
removal efficiency.
Each unit shall be able to accommodate specified flow rate feed slurry having a grit
concentration of approximately 2% to 4% at the maximum specified pressure drop.
Each cyclone will incorporate one replaceable vortex finder and one replaceable apex.
Under the above operating conditions, each cyclone will recover 95%of 105 micron
particles Theunderflow volume will be approximately 5% to 10% of the feed volume.
The largest spherical solids size flowing through the cyclone at any time, shall not
exceed 1/2” (1/3 of the apex diameter size).
Construction:
Materials of Construction:
Feed Entry: ASTM A240/A479 316 stainless steelinvolute type.
Housing, Cyclone Cylinder and Cone: ASTM A240/A479 316 stainless steel.
Apex Housing: ASTM A240/A479 316 stainless steel.
Lining: Each section independently lined with replaceable liners.
Components:
Vortex Finder: Constructed of unlined Ni-hard material having a minimum
hardness of 500 Brinell. A quick connection "device" shall be provided between
the apex and lower cone section to allow removal of material, which may clog
the apex, without disconnecting any piping or the cyclone itself.
Appurtenances:
Provide a pressure gauge and diaphragm with a 3/8" connection.
Fasteners: Type 316 stainless steel.
2.3GRIT CLASSIFIER
Unit Description:
Classifier mechanism shall be either of the helicalscrew type designed to maintain
velocities to retain organic matter in suspension and remove the non-organic material
of a size retained on a 50-mesh screen.Unit shall consist of a trough with its inlet
hoper, a screw mounted in the trough and powered by a motor reducer assembly.
Trough:
Material of Construction: Type 316stainless steel, 3/16-inch thick
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Trough lower end shall have an end plate on which is flange mounted
greaseablepacking gland seal.
Packing gland seal shall be continuously greased through an internal lantern
ring by means of a spring-loaded grease cup.
Provide a drain connection at the lower end.
Upper end of the trough shall have an end plate to receive the screw conveyor
drive, which supports other end of the screw.
CONTRACTOR shall provide a heat-traced discharge outlet at the upper end of
the trough.
Helical Screw Type:
Incorporate in its design to permit normal maintenance without requirement for
draining tank.
Material of Construction: Type 316stainless steel, withreplaceable hardened
wearing surfaces.
Screw shall be of standard flight and full pitch design.
Inlet Hopper:
Full-flare, pooling area of 8.5square feet(maximum),constructed of 3/16-inch
Type 316stainless steel with supports.
Provide overflow weir to maintain constant water level and control discharge of
degritted water.
Lamellar plates may be provided to increase settling efficiency but are not
required.
Provide 18”x18” hinged access hatch.
Washwater: Provide electric solenoidvalve, pressure and flow control, and unit piping
for Washwater. Washwater will be non-potable treated wastewater.
A 3/8-inch diameter316 stainless steelpipe with a spray nozzle shall be provided to
wash the grit being carried by the screw conveyor.
Grit cyclone and grit dewatering classifier shall be completely enclosed for odor
control.There shall be a 4-inch pipe connection with a blind flange included.
Discharge Collection Hopper and Chute:
Hopper shall have minimum 60 degree inclined sides, constructed of 3/16-inch
Type 316stainless steel with supports. Dimensions shall be as indicated on the
Drawings. Interior surface of hopper shall be Teflon coated.
Chute shall be 2’x2’and constructed of 3/16-inch Type 316stainless steel.
Interior surface of chute shall be Teflon coated.
Hopper and chute to be supplied by the CONTRACTOR.
Drive Unit:
Consist of TEFC, ball bearing, constant-speed, heavy duty motor with direct drive or
V-belt drive to a speed reducer with oil-tight housing.
Provide a belt guardif required.
Output shaft of the reducer shall be direct connected to the upper end of the screw
conveyor.
Speed of the screw shall not exceed 20 rpm.
Bearing: B-10 life 50,000 hours minimumat maximum load.
Motor Size: 1HP. Classifier screw motors shall be spaced a minimum of two feet
apart.
2.4PERFORMANCE REQUIREMENTS
Performance Description:
Designed to separate the grit from the slurry mixture removed from the grit vortex
chamber and transferred by pumping to the grit cyclone/grit classifier system. The
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water shall fall into the inlet hopper where a constant volume of water is
accumulated. This water volume shall act effectively as a classifier, letting the grit
settle to the bottom of the hopper. In the trough of the hopper, the slow rotation of
the screw moves the accumulated grit using the Archimedes screw principle to the
discharge outlet.
Comply with performance requirements specified, as determined by testing
manufacturer's standardassemblies representing those indicated for this Project.
The grit cyclone, in combination with the grit classification unit, shall be capable of
removing at least ninety-five (95) percent of 50mesh grit, having a specific gravity of
2.65 or greater, at the specified hydraulic flow rate and pressure drop.
Structural Performance: All equipment, supports, anchors and fasteners shall be of adequate
size and strength to withstand loads associated with turbulence, debris, thrusts from liquid
movement, thermal expansion and contraction and other loads encountered under operating
conditions.
Operation: Equipment shall be designed and capable of both continuous and intermittent
operation.
2.5FABRICATION
Stainless Steel Fabrication:
Conform to AISI 316and ASTM A240-78a for welded parts and assemblies. Fabricate
from 316stainless steel sheets and plates with 2D finish.
Conform to AISI 316and ASTM A240-78a for non-welded parts and assemblies.
Fabricate from 316stainless steel.
Passivate all stainless steel surfaces by wire brushing, pickling, and neutralization.
Field Work:
No cutting or welding will be permitted in the field.
Only bolted connections may be made in the field.
Use a minimum of two 3/4-inch bolts on structural connections and two 5/8-inch bolts
on secondary connections.
2.6FINISHES
All equipment items except stainless steel shall receive surface preparation, prime coating
and finish coating in the factory in accordance with Section09 91 00 “Painting and
Protective Coatings”. Finish coating colors shall be selected by the OWNER from finish color
charts to be provided in shop drawing submittals. Furnish one gallon of touch up paint for
installation CONTRACTOR to apply.
All stainless steel surfaces shall be cleaned and welds shall be brushed with Type
316stainless steel brushes. Electro bead blast or chemically treat all external non-welded
stainless steel to a uniform finish.
Motors and hydraulic units shall have a factory finish. Factory finishes shall conform with the
requirements in Section 09 91 00 “Painting and Protective Coatings”.
Machined, polished, and non-ferrous surfaces shall be coated with a corrosion prevention
compound.
2.7GEAR MOTOR
Comply with NEMA designation, temperature rating, service factor, enclosure type, and
efficiency requirements for motors specified in Section 40 05 93 “Common Motor
Requirements for Process Equipment”for motors. Requirements of this Section supersede
any conflicting requirements of Section40 05 93.
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Motor Sizes: Motor size and detail requirements shall be as indicated in the Design and
Performance Criteria table at the End of Section. Motors shall be properly sized so that the
driven loads will not require the motorto operate in service factor range above 1.0 along
the complete operating range.
If a motor horsepower rating larger than specified is offered as a substitute and accepted,
provided required changes in conductors, motor controllers, overload relays, fuses, switches
and other related items with no change in the Contract price.
Motors shall be rated for Class I, Division IIlocations.
Gear Motor Description, if required:
Output shaft of the motor shall be direct coupled to the gear reducer and the output
shaft of the gear reducer shall be direct coupled to the screw shaft.
The entire motor drive assembly shall pivot at the shaft centerline. Provide manually
operated lifting device attached to lower bearings for raising the spiral for inspection if
bearings are submerged.
Gear Reducer:
Parallel-helical type with 1.4 minimum service factor, having anti-friction bearings with
high overhang load properties, and double lip temperature oil seals riding on precision
ground shafts.
Gears shall be made of hardened, heat-treated forged steel as per AGMA II
standards.
Gearing shall be oil lubricated.
2.8INSTRUMENTATION AND CONTROLS CONTROL PANELS
General Requirements
Refer to Section 40 05 91 “Common Control Panel Requirements for Process
Equipment” for general requirements of control panels requirements.
Control panel shall be provided with main circuit breaker, starters, PLC, control power
transformer, lights, switches, relays, terminal strips, etc. for a complete and
operational system.
All instrumentation, control and electrical components provided under this section shall
comply with the requirements on the Drawings and Divisions 26 and 40.
Control Panels shall be NEMA 4X 316stainless steel,oversized enclosure, with a three
point latching handle and rated for 480 V, 3-Phase, 60 hz.
Provide thermostatically and humidity-controlled heaters and close loop air conditioning
in the panel if required to maintain proper operating temperature range for the
equipment minimize condensation.
All internal components shall be mounted and secured to the removable back plane
assembly.
The entire Grit Train Control System shall be furnished, configured and completely
commissionedby the EQUIPMENT SUPPLIER.
Furnish one (1) control panel for per Grit System Train (existing 15hp Grit Pump, Grit
Classifier and Washing Equipment) for a total of twopanels. Furnish one (1) control
panel for the Grit System for (two existing 15 hp Grit Pumps, and 2 Grit Classifiers and 5
Washing Equipment.The panel shall be mounted on slotted support channel and the
top mounted no higher than 5’-6” above the walkway/floor and the bottom no lower
than 2’-6” above the walkway/floor.
Grit System Train Control Panel
Provide control system for equipment system, but not limited to the fluidization valve,
grit pump, grit classifier and required solenoid valves. This list is not intended to
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completely depict all of the functional requirements of the control system provided
under this Section. The EQUIPMENT SUPPLIER shall provide all additional
instrumentation and controls necessary to produce a safe and operable system.
Each grit system train shall be provided with one (1) PLC based control system
furnished by the EQUIPMENT SUPPLIER in each train panel. Grit system train control
system shall be furnished, configured and completely commissioned by EQUIPMENT
SUPPLIER.
Plant Control System (SCADA) Interface:
The grit system train PLCs shall be capable of communicating all instrument readings
and system alarms to the plant control system via Ethernet/IP multimode fiber optic
connection.
Manufacturer shall supply DIN rail mounted N-Tron model 308FX2-N-SCethernet
switch or engineer approved equal to support remote communications with the plant
master controlpanel. Manufacturer shall supply a 12 strand DIN rail mounted fiber
optic patch panel.
Manufacturer shall make available PLC programming addresses and control narratives
to support SCADA communication.
The EQUIPMENT SUPPLIER shall provide complete electronic copies of all PLC, I/O and
configuration program data before shipment of the equipment for use in configuring
the plant control system and shall provide updated versions of this information during
the field commissioning start up and testing, if necessary, including final version before
acceptance of the system. EQUIPMENT SUPPLIER shall supply the software program
and all necessary software components compatible with the PLC to provide the Owner
with the capability to troubleshoot PLC.
CONTRACTOR will be responsible for ensuring there is communication and monitoring
capability between the PLC and the plant control system.
Panel shall have the following controls mounted on the panel face:
ON/OFF/AUTOMATIC for each drive motor
ON allows the equipment to be started from the panel
OFF allows the equipment to be stopped from the panel
AUTO allows the equipment to be started, stopped, from the described
sequence of operation
OPEN/CLOSE/AUTOMATIC for each valve
OPEN allows the valve to be opened from the panel
CLOSE allows the valve to be closed from the panel
AUTO allows the valve to be opened, closed, from the described sequence
of operation
RUN, FAIL, and OFF push-to-testLED indicating lights for each piece of
equipment.
Open and Close push-to-test LED indicating lights for each valve.
Fail reset button for each piece of equipment
Emergency stop push button
The minimum shall be provided with the panel.
Main circuit protective device
PLC with Ethernet/IP communications, over multimode fiber optic.
NEMA rated contractors for each piece of equipment
Fused sealed oversized control power transformer.
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Combined sounder and LED beacon for annunciating of failure. Beacon/horn shall
be mounted separately from enclosure by CONTRACTOR.
Ambient temperature controlled.
Condensate drain.
Provide engraved nameplates for each function.
Provide terminal strips in enclosure for termination of device, no direct
termination to relays, VFDs, starters, etc. allowed.
2.9ACCESSORIES
Anchor Bolts: Provide template and Type 316 stainless steel anchors and fasteners in
accordance with Section050523 “Metal Fastenings and Anchor Bolts,” as shown on the
Drawings, and as recommended by the EQUIPMENT SUPPLIER. Size and locations as
required by EQUIPMENT SUPPLIER. EQUIPMENT SUPPLIER shall size all anchor bolts and
fasteners required of ample size and strength for the intended purpose, minimum of ½-inch
diameter. Fastener sizing calculations shall be provided as an informational submittal.
CONTRACTOR shall furnish and install all anchor bolts and fasteners in accordance with the
equipment supplier’s installation instructions.
Equipment Identification Plates:EQUIPMENT SUPPLIER shall furnish a 16-gauge 316
stainless steel identification plate securely mounted on the equipment in a readily visible
location. The plate shall bear 1/4-inch die-stamped equipment identification number
indicated in this Section and/or on the Drawings.
Lifting Lugs: Individual equipment and/or each field disassemble part weighing over 60
pounds shall be provided with lifting lugs
Initial Supply of Lubricants: EQUIPMENT SUPPLIER shall indicate types, brands, and
quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants and shall comply with all
equipment supplier recommended procedures.
2.10TOOLS, SPARE PARTS AND MAINTENANCE MATERIALS
TheEQUIPMENT SUPPLIERshall supply one (1) set of spare parts for all components
exposed to operational wear during normal equipment service.
Spare parts shall include, but not be limited to the following if they are used in the
equipment the manufacturer provides:
One (1) set of spare liners and gaskets for each cyclone.
One (1) set drive bearings.
One (1) set oil seals and gaskets.
One (1) worm gear set.
One (1) set upper and lower screw bearings.
One (1) drive belt.
One (1) upper gasket.
One (1) shaft seat.
Two (2) trunnions per washer.
Special tools necessary to maintain the equipment.
All spare electrical components per Divisions 26 and 40.
Other parts recommended by the manufacturer as typically needed in the first
two years of operation.
Equipment Lubricants: The EQUIPMENT SUPPLIER shall indicate and verify types, brands,
and quantities of initial lubricants, oil, grease, etc. necessary to startup equipment.
CONTRACTOR shall provide and install the recommended lubricants.
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Spare parts shall be packed in sturdy containers with clear, indelible identification markings
and shall be stored in a dry, warm location until transferred to the OWNER at the conclusion
of the project. Each part shall be labeled with part numbers which correspond to the
Operation and Maintenance Data submitted in accordance with Section 01 78 23 “Operation
and Maintenance Data.”
EXECUTION
3.1EXAMINATION
Verify structures, pipes, and equipment are compatible.
3.2PREPARATION –NOT USED
3.3INSTALLATION
CONTRACTOR to install equipment per this Section and the EQUIPMENT SUPPLIER’S
installation instructions.
3.4FIELD QUALITY CONTROL
EQUIPMENT SUPPLIER Services
P EQUIPMENT SUPPLIER Field Representative: The EQUIPMENT SUPPLIER Field
Representative shall be present at the project site or classroom designated by
OWNER for minimum person-days and trips provided in the table below. Each person-
day shall be defined as eight(8) hours duration, exclusive of travel. The EQUIPMENT
SUPPLIER Field Representative shall revisit the jobsite as often as necessary to
correct deficiencies.
Table 1–Manufacturer Field Services
Number of
Work DescriptionNumber of Trips
Person Days
Installation assistance and inspection21
Functional and performance testing21
can be combined
Pre-startup classroom or site training1
with facility startup
Facility startup21
Post-startup training of OWNER’S personnel11
Functional Tests: Prior to plant startup, the CONTRACTOR, with the assistance of the
EQUIPMENT SUPPLIER’s representative, shall inspect all equipment for proper assembly and
alignment, quiet operation, and proper operation.
Performance Tests: The EQUIPMENT SUPPLIER’s representative shall conduct performance
test on the equipment to certify compliance with the performance requirements.
Place each piece of equipment in the system in operation until the entire system is
functioning. All components shall continue to operate without alarms or shut downs,
except as intended, for eight consecutive hours to be considered ready for facility
startup.
Operate the equipment through the design performance range consistent with
available flows. Adjust, balance, and calibrate and verify that the equipment, safety
devices, controls, and process system operate within the design conditions. Each
safety device shall be tested for proper setting and signal. Response shall be checked
for each equipment item and alarm. Simulation signals may be used to check
equipment and alarm responses.
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3.5SYSTEM STARTUP
Startup of the facility shall be in accordance with Section 01 75 25“Equipment Testing and
Startup.” Installation Assistance and Inspection. After Equipment Installation and before
start up, the CONTRACTORand EQUIPMENT SUPPLIER Field Representative shall inspect
the installation of the equipment. A preliminary running period (as applicable) will be
provided for the CONTRACTOR to make field adjustments with the EQUIPMENT SUPPLIER
Field Representative. CONTRACTOR shall submit a report for EQUIPMENT SUPPLIER
approval of equipment installation.
Functional Test. CONTRACTOR to start up equipment with EQUIPMENT SUPPLIER Field
Representative. Equipment shall be able to run in manual mode with all associated piping,
electrical and equipment installed to show proper operation of the equipment. Functional
Test shall be 5 days of uninterrupted service. The CONTRACTOR shall be responsible for
equipment operation for the 5-day period. Any delays or additional person days and trips
required for EQUIPMENT SUPPLIER Field Representative to perform Functional Testing
beyond what is specified is the responsibility of the CONTRACTOR. Functional Test can be
run with clean water to demonstrate equipment operation.
Performance Test and Initial Training. CONTRACTOR and EQUIPMENT SUPPLIER Field
Representative to start up equipment in Automatic Mode (Normal Operation). Equipment
shall run in two modes, normal operation and peak flow conditions. Contractor and
EQUIPMENT SUPPLIER Field Representative should demonstrate any alarms, lead lag
conditions, or total auto mode or other conditions related to equipment operation.
Performance Test shall run with uninterrupted service for 30 days. Performance Test shall
be run with wastewater under normal operating conditions. If equipment fails before 30
days, then EQUIPMENT SUPPLIER shall correct problems at their own expense and restart
the 30-day Performance Test. EQUIPMENT SUPPLIER and CONTRACTOR is responsible for
equipment operation during the 30-day Performance Test. EQUIPMENT SUPPLIER shall
perform initial training at the end of the 30-day Performance Test for owner’s
representative. Training shall be with a draft of the full Operation and Maintenance
Manuals. Upon completion of Performance Test and Training, The OWNER shall consider
that equipment substantially complete and start the warranty period.
Post-Startup Training. EQUIPMENT SUPPLIER will perform additional training at a time
mutually agreeable to the OWNER and EQUIPMENT SUPPLIER to take place no earlier than
30 days after equipment substantial completion and no later than 90 days after substantial
completion.
3.6CLOSEOUT ACTIVITIES
A copy of all information from functional tests including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
END OF SECTION
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0537-038-01GRIT CLASSIFYING AND WASHING EQUIPMENTJANUARY 2023
Table 2 – Grit Classifier Design Conditions
Parameter Value
Environmental Conditions
Site Elevation 33 feet
Barometric Pressure 14.68 psia
Relative Humidity, Upper Range 100%
Relative Humidity, Lower Range 35%
Inlet/Ambient Temperature, Upper Range 110°F
Inlet/Ambient Temperature, Lower Range 10°F
Ambient Temperature Control None
Design Conditions
Tag Numbers XXX-XXXX, XXX-XXXX
Quantity Two (2)
Location Headworks
Cyclone Inlet Size 4 Inches
Cyclone Outlet Size 6 Inches
1
Dewatering Screw Diameter12 inches, minimum
1
Dewatering Screw Length, min.8.5 feet
Motor Information
HP, min 1
Speed, RPM 1800
Starts per hour 15
Power 480V/3PH/60Hz
Inverter Duty Rated, Minimum Turndown % No
Capacity 300 GPM
1
Note: Specified dimension can vary based on manufacturer.
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0537-038-01 GRIT CLASSIFYING AND WASHING EQUIPMENT JANUARY 2023
SECTION 46 43 21
CIRCULAR CLARIFIER EQUIPMENT
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 1 Specification Sections, apply to this Section.
B. Related Sections:
1. Section 09 91 00 – Painting and Protective Coatings
2. Section 40 05 93 - Common Motor Requirements for Process Equipment
3. Section 40 05 91 - Common Control Panel Requirements for Process Equipment
4. Division 26 - Electrical
1.2 SUMMARY
A. Furnish, install, startup, test and make ready for operation two (2) secondary wastewater
treatment clarifiers as described as follows:
1. Two (2) secondary clarifier at 100-foot diameter (Secondary Clarifier No. 1 and 2)
a. Tag No. BRD-MLR-CLR61 and BRD-MLR-CLR62
2. The secondary clarifier equipment includes:
a. Drive mechanism complete with gear reduction, motor, and torque overload
device.
b. 2205 duplex stainless steel truss rake arm assembly with rake blades, stainless
steel squeegees, and suction pipes.
c. Center column with feedwell and energy dissipating inlet.
d. Sludge collection system.
e. Scum removal mechanism.
f. All necessary controls, supports, and connections necessary for a complete and
operable system.
g. Control panel with alarm light.
B. General
1. Each mechanism shall be center pier supported and include a stationary center pier
supporting a turnable drive and an existing access bridge and drive platform with a
new rotating drive cage supporting flight arms. Mixed liquor shall flow upwards into the
energy dissipating feedwell. The equipment shall be designed to effectively settle
mixed liquor suspended solids and convey settled solids to the vertical suction pipes.
The vertical pipes shall connect to collection troughs at the surface of the clarifier, and
sludge shall be diverted to the RAS pipe concentric with the influent pipe. RAS pipe
shall penetrate the influent pipe and connect to the existing RAS pipe as shown on the
drawings. Effluent will be collected uniformly across an existing weir to an external
launder.
2. The drawings and specifications cover certain required features of the equipment, but
do not purport to cover all details entering into its design.
C. MANUFACTURER shall be responsible to coordinate the testing and installation of the
equipment and motors and shall be responsible for the adequacy and compatibility of the
clarifier mechanism, motor, and controls with any existing equipment. MANUFACTURER shall
coordinate with the CONTRACTOR on required controls and connections.
1.3 REFERENCES
A. References: Following is a list of standards, which might be referenced in this Section:
PLUMMER ASSOCIATES, INC. 46 43 21 - Page 1 of 20 BID SET
0537-038-01 CIRCULAR CLARIFIER EQUIPMENT JANUARY 2023
1. American Bearing Manufacturer’s Association (ABMA):
a. 9 - Load Ratings and Fatigue Life for Ball Bearings
b. 11 - Load Ratings and Fatigue Life for Roller Bearings
2. ASTM International (ASTM):
a. A48 –Specification for Gray Iron Castings
b. A276 – Specification for Stainless Steel Bars and Shapes
c. A572 – Specification for High-Strength Low-Alloy Columbium-Vanadium
Structural Steel
3. AWS D1.6 Structural Welding Code for Stainless Steel.
4. American Institute of Steel Construction (AISC).
5. National Electrical Manufacturer’s Association (NEMA): MG-1, Motors and Generators.
6. National Fire Protection Association (NFPA): NFPA 70, National Electric Code.
1.4 SYSTEM DESCRIPTION
A. General Requirements
1. All equipment including controls specified herein shall be specifically designed for this
service and the environment encountered in this installation. The environment will be
moist, and corrosive, exhibiting hydrogen sulfide, other corrosive gases, and chlorides
encountered in municipal wastewater treatment plants and marine environments.
2. Equipment shall be designed and capable of continuous operation receiving mixed
liquor from the aeration basins.
3. All equipment, supports, anchors and fasteners shall be of adequate strength to
withstand loads associated with starting, turbulence, thrusts from liquid movement,
thermal expansion and contraction and other loads encountered under normal
operating conditions. Structural fasteners shall be AISI 316 stainless steel for exposed
service and Type 2205 duplex stainless steel for submerged service, equipment
anchorage and hardware shall be AISI type 316 stainless steel for exposed service and
Type 2205 duplex stainless steel for submerged service.
4. The equipment, sizes, materials, and arrangements described in this specification
section are based on recommendations by equipment manufacturers and shall be
considered minimum limits of acceptability. The equipment manufacturer shall be
responsible for design, arrangement, and performance of all equipment supplied under
this section. Arrangements other than those shown on plans shall be subject to
ENGINEER's approval.
B. Clarifier Mechanism
1. The clarifier mechanisms shall be a center drive type, supported on a stationary
influent pier, with the flow entering at the bottom of the influent column and flowing
upward through the energy dissipating inlet and into the feedwell.
2. Clarifier mechanism shall collect settled sludge at the bottom of the tank, convey
upward through pipes to collection troughs, and exit through the RAS pipe concentric
to the influent pipe. Scum shall be removed from the center feedwell and along the
tank’s periphery.
3. Table 1 gives the secondary clarifier design parameters.
Table 1: Secondary Clarifier Design Parameters
Secondary Clarifier
Equipment Location
Nos. 1 & 2
(100' Diameter)
Individual Operating Conditions per
Clarifier
6.02 MGD
Design flow including 100% recycle:
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Table 1: Secondary Clarifier Design Parameters
Secondary Clarifier
Equipment Location
Nos. 1 & 2
(100' Diameter)
22.02 MGD
Peak flow including recycle:
2.02 MGD
Design return activated sludge flow:
2.02 MGD
Peak return activated sludge flow:
48 lbs/sf
Peak solids loading, maximum:
Clarifier Dimensions
100’-0”
Tank diameter:
15.49’
Side water depth:
1:192
Floor slope (V:H):
3.01’
Free board:
Center Pier
3'-6"
Center pier outside diameter:
Drive Mechanism
30”
Spur gear pitch diameter, minimum:
0.5 HP
Motor horsepower, minimum:
30,000 ft-lbs
AGMA rated torque, minimum:
60,000 ft-lbs
Momentary peak torque, minimum:
8-10 ft/min
Rake tip speed:
Minimum Torque Requirements
100% of design
Alarm:
120% of design
Shut-off:
1.5 PERFORMANCE REQUIREMENTS
A. The central influent pier and column assembly shall be designed to support the drive
mechanism, the sludge collection mechanism, scum removal system components, utility
piping, access bridge beams and walkway. The drive cage and all rotating equipment shall
be designed to withstand twice the continuous 20-year operating torque without exceeding
the material yield strength of the structural members.
B. The drive unit shall be structurally designed to operate in one direction, but the equipment
can be “jogged” in reverse. Reverse rotation will not be a normal or continuous operation.
However, the cage and equipment shall be designed for reverse rotation.
1.6 SUBMITTALS
A. Submittals shall be prepared and submitted in accordance with Section 01 33 00, “Submittal
Procedures” for each type of product specified. Include construction details, material
descriptions, dimensions of individual components and profiles, rated capacities, operating
characteristics, electrical characteristics, and furnished specialties and accessories. Shop
Drawings: For each unit. Include plans, elevations, sections, details, and attachments to
other work.
1. MANUFACTURER shall provide a copy of this Section and indicate for each specification
item in this Section that the requirement is acknowledged. All deviations from the
contract documents shall be clearly identified in a separate list.
2. Detail equipment assemblies and indicate dimensions, weights, loads, required
clearances, method of field assembly, components, and location and size of each field
connection. Include details of drive assembly with overload protection system, center
pier and anchoring requirements, scum removal and skimmer assemblies, sludge
collection equipment, and sludge collection trough. Include descriptions and provisions
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for adjustments and alarms on operating components. Indicate extent of shop
fabrication and field joint types and locations.
3. Welding certificates. A statement shall be included that indicates the latest version of
Structural Welding Code AWS D1.6, “Stainless Steel” is met.
4. Welding data, including the filler materials used.
5. Mill certificates for all stainless steel grades supplied. Duplex stainless steel supplied
shall be in accordance with the composition in Paragraph 1.7.D.
6. Performance data showing capacity, horsepower demand, and torque requirements
over the entire operating range.
7. Detailed specifications and data describing the materials of construction, material
thickness and coatings for all components.
8. AGMA torque and strength calculations and AMGA calculations for the main spur gear
drive. Provide torques at which collector is designed to operate continuously, where
alarm is set and where collector will stall.
9. Speed of rake arm rotation.
10. Submit design calculations of equipment design and certification of conformance with
specified requirements by Texas professional engineer.
11. Submit flow quantity calculations and graphs for skimmer mechanism specified.
12. Submit data that verifies the feed system is capable of uniformly distributing flow
throughout the tank over the flow range specified.
13. Submit performance data verifying the sludge collector system design proportionally
removes sludge from the entire tank bottom over the flow range specified.
14. Complete test procedure for field testing the sludge collector mechanism for the AGMA
rated torque.
15. Complete information on electric motors furnished, including make and type of motor,
brake horsepower, locked rotor current at full voltage, motor dimensions and weight,
and any other information required in Section 40 05 93, “Common Motor Requirements
for Process Equipment”.
16. Complete motor nameplate data, as defined by NEMA, motor manufacturer, and
include any motor specifications.
17. Wiring Diagrams: For power, signal, and control wiring diagrams, including terminals
and numbers.
18. Documentation demonstrating factory finish is equivalent to finish system specified in
this Section.
B. Information Submittals:
1. Factory functional and performance test reports and log.
2. Manufacturer’s Certification of Compliance.
3. Special shipping, storage and protection, and handling instructions.
4. Manufacturer’s instructions for installation.
5. Manufacturer’s Certificate of Proper Installation.
6. Suggested spare parts list to maintain the equipment in service for a period of one
year. Include a list of special tools required for checking, testing, parts replacement,
and maintenance with current pricing information and location of nearest stocking
distributor of spare parts.
7. List special tools, materials, and supplies furnished with equipment for use prior to and
during startup and for future maintenance.
C. Operation and Maintenance Data: For each clarifier system to include in operation and
maintenance manuals. Provide in accordance with Section 01 78 23, “Operation and
Maintenance Data.”
D. Start-up and test schedule with test procedures in accordance with Section 01 75 25,
“Equipment Testing and Startup”.
E. Equipment installation report with field test data and test records in accordance with
Section 01 33 00, “Submittal Procedures”.
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F. Warranties and service agreements.
G. All deviations from contract documents shall be submitted separately by CONTRACTOR as a
Contract Modification Request.
H. Any other information necessary for the ENGINEER to determine compliance with the
specifications.
I. Partial or incomplete submittals will not be received by the ENGINEER.
1.7 QUALITY ASSURANCE
A. MANUFACTURER Qualifications: Equipment shall be the product of a MANUFACTURER
having at least twenty (20) similar system installations in the United States of the type
proposed, each with a minimum of five (5) years of satisfactory service.
B. Equipment of each type specified in this section shall be supplied by a single
MANUFACTURER. All equipment shall have a Type 316 stainless steel MANUFACTURER’s
nameplate securely affixed in a conspicuous place on the equipment showing the ratings,
serial number, model number, manufacturer and other pertinent nameplate data.
C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,
by a qualified testing agency, and marked for intended location and application.
D. All Type 2205 Duplex Stainless Steel shall be pickled and passivated and meet the following
composition requirements:
1. Carbon: 0.03%
2. Chromium: 21.0 – 23.0%
3. Nickel: 4.5 – 6.5%
4. Molybdenum: 3.0 – 3.5%
5. Nitrogen: 0.08 – 0.20%
6. Manganese: 2.00%
7. Pitting Resistance Equivalent Number (PREN): 33 – 35
E. All structural 2205 duplex used for equipment fabrication shall conform to the requirements
of the Standard Specifications for Steel for Bridges and Buildings and UNS S32205. All
welding shall conform to the latest standards of the AWS. Continuous seal welds shall be
provided at all welded joints. Skip welds will not be permitted.
F. All 2205 duplex structural components shall be so designed that the stresses developed
under the specified conditions will not exceed the allowable stresses defined by the AISC
standards and the aforementioned standards. Except where specifically indicated otherwise,
all plate and structural members designed for submerged service shall have a minimum
thickness of 1/4 inch. AISC recommended limits for slenderness shall not be exceeded on
any member.
1.8 PROJECT CONDITIONS (NOT USED)
1.9 DELIVERY AND STORAGE
A. Delivery, storage, and handling shall be in full accordance with manufacturer's instructions
and Section 01 60 00 “Product Requirements”. Motors other electrical components shall be
stored as indicated in Section 40 05 93, “Common Motor Requirements for Process
Equipment”.
B. Products shall be handled shipped and stored in such a manner as to prevent or minimize the
possibility of free iron contamination. Suspected free iron contamination such as evidenced
by unusual stains or discoloration, shall be verified by ferroxyl testing by the Contractor in
the presence of the Owner or OAR and in accordance with ASTM A380E.
1.10 WARRANTY
A. Extended Equipment Warranty: Refer to Specification 01 78 36, “Warranties” for extended
equipment warranty.
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B. All equipment furnished under this section shall have a special equipment warranty, in
accordance with the Contract Documents, for a period of five (5) years from the date of
Substantial Completion. The cost of removal, shipment, repair, and installation by
CONTRACTOR shall be included in the warranty and correction of defective work.
C. Manufacturer shall provide labor on-site to diagnose and correct any problem that is not
resolved via telephone communication with plant personnel within 72 hours or that reoccurs
during this warranty period.
D. Manufacturer shall provide a factory field representative within two weeks of problem
occurrence, for non-emergency repairs. Cost for the removal, shipment, repair and
installation by CONTRACTOR shall be included in warranty, as well as correction of defective
work.
1.11 MAINTENANCE
A. MANUFACTURER shall maintain a complete stock of spare parts commonly needed for the
equipment specified at a location within the State of Texas or shall furnish spare parts to the
plant within 24 hours of request.
B. The following spare parts shall be furnished for each of the clarifier packages supplied:
1. One (1) set of the following spare parts shall be furnished for each clarifier provided
under this specification:
a. One set of strip liners and drive seals, if used.
b. Five shear pins, as applicable.
c. One each of sight glasses or oil gauges.
2. Special tools required for maintenance or adjustment.
3. All spare electrical components per Section 40 05 91 “Common Control Panel
Requirements for Process Equipment” and Section 40 05 93, “Common Motor
Requirements for Process Equipment.
4. Other items as recommended by the manufacturer.
C. Spare parts shall be packed in sturdy containers with clear, indelible identification markings
and shall be stored in a dry, warm location until transferred to the OWNER at the conclusion
of the project.
D. MANUFACTURER shall furnish and verify installation of all lubricants required to place the
equipment in service.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. The following manufacturers are listed as acceptable in order to set a definite standard of
quality and performance. Listed manufacturers and products are expected to fully comply
with the specifications.
1. OVIVO, Model C3S-SRD
2. Walker
3. Westech
4. Envirodyne
2.2 EQUIPMENT
A. Fabricated assemblies shall be shipped in the largest sections permitted by carrier regulations
and match-marked for ease of field erection. The shop drawings shall clearly indicate the
number of subassemblies proposed for each mechanism and the contents.
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B. All shop and field welding shall conform to current Standard Welding Code, AWS D1.1 and
AWS D1.6. All welded connections shall develop the full strength of the connected elements
and all joined or lapped surfaces shall be completely seal welded with a minimum 3/16-inch
fillet weld and wrapped. Skip welding shall not be allowed. All welders shall be certified,
acceptable to the OWNER, and be permanent employees of the Contractor or
manufacturer/fabricator.
C. Sharp projections of cut or sheared edges shall be ground to a radius by multiple passes of a
power grinder as required to ensure satisfactory coatings adherence.
D. No underwater bearings, chains or drive components that carry vertical thrust loads shall be
permitted. All gearing shall be completely enclosed and oil or grease lubricated.
E. All aluminum shall be type 5052, 6061, 6063, or 2014 alloy unless noted otherwise.
2.3 STRUCTURAL STEEL
A. All structural steel shall conform to the current edition of ASTM A240 and ASTM A479. Steel
pipe used for structural members shall conform to ASTM A790 and ASTM A928. All structural
steel components of the clarifier mechanism, supports, trusses, sludge collection, etc. shall
be Type 2205 duplex stainless steel for all submerged components and Type 316 stainless
steel for all exposed components. The drive assembly shall receive paint per Section 09 91
00, “Painting and Protecting Coatings”.
B. Minimum metal thickness for steel plates and structural members which are submerged or
within 6 inches of the maximum water surface elevation shall be 3/16-inch. Minimum metal
thickness for steel plates and structural members located 6 inches above the maximum water
surface elevation shall be 3/16-inch. The minimum dimensions for a structural member shall
be 2-inch by 2-inch by 1/4-inch.
C. Duplex material shall be manufactured via the electric arc or electric furnace process and
refined by AOD or equivalent process. Duplex material shall be solution annealed to 1900-
1975°F followed by water quench. If no hardness maximum value is specified by the material
specification, hardness shall be maximum of HRC 28, HB 271 or HV 290.
D. The maximum allowable stresses in tension and compression on the net section at any
member shall be 80 percent of the values for allowable stresses listed in the AISC
Specification for "Design Fabrication and Erection of Structural Steel for Bridges and
Buildings." All steel design shall be in accordance with the AISC Manual of Steel Construction,
latest edition, and the Uniform Building Code (UBC), latest edition.
E. Slenderness ratios for tension members shall be not greater than 240, and for compression
members not greater than 200. All individual members of trusses shall be treated as
compression members for calculation of slenderness ratios.
F. All members shall be fabricated as true structural shapes where such shapes are standard
mill shapes. Where standard mill shapes are not manufactured, bending of standard shapes
will be permitted providing the manufacturer can prove that no loss in structural strength
results from the bending.
G. Members that are bent, deformed, or otherwise damaged during fabrication, storage,
shipment, installation, or checkout may not be straightened and reused. All damaged
members shall be promptly replaced with newly fabricated members.
H. Connections shall be shop welded or field bolted. Field welding will not be permitted.
I. All nuts, bolts, washers, anchor bolts, etc., shall be Type 316 stainless steel for exposed
components and Type 2205 duplex stainless steel for submerged components.
2.4 WELDING
A. Weld Preparation and Alignment:
1. Misalignment between components welded together shall not exceed 1/8 times the
wall thickness of the thinner of the two parts to be joined with a maximum of 1/ 8"
(3.2 mm.) In case of single welded joints, the misalignment shall not exceed 1/16" to
ensure full penetration and full fusion at the bottom of the joint over its full length.
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2. All welds subjected to pressure shall be full penetration, full fusion and double welded
where possible. Welds, which are accessible from one side only, may be single welded,
provided that full penetration and full fusion can be assured by a proper welding and
inspection procedure.
3. The following additional requirements apply to 2205 duplex stainless steel welds:
a. Weld joint design must avoid autogenous regions in the weld solidification (i.e.
filler must be used throughout).
b. All surfaces to be welded shall be ground to shiny metal. The weld joint shall be
clean, dry, and free of contamination prior to welding.
c. Carbon steel tools or tools used previously in the fabrication of carbon steel shall
not be used on stainless steel. Stainless steel surfaces shall not be allowed to be
contaminated with iron or carbon steel filings and dust.
d. All plasma cut edges shall be ground to remove the chilled surface. All burrs,
rough edges, etc., shall be removed by filing, grinding, etc. Any grinding burrs or
scale should be removed to maintain complete fusion and penetration.
e. Preheating of weld joints shall not be done, unless the substrate is below 50 ºF,
in which case the weld joint should be preheated to prevent condensation of
moisture in the weld area. In no case shall the preheat temperature exceed
200ºF.
B. Welding:
1. The following electrodes filler materials are to be used for all 2205-to-2205 joints:
a. FCAW filler wire to be Oxford Alloy 2209T-1 or WEL FCAW 329J2L
b. GTAW filer wire to be Metrode ER329N or OXFORD ALLOY2209 or WEL TIG
329J2L
c. SAW filler wire to be METRODE ER329N/SSB FLUX or WEL SUB 329J2L/F25 or
Oxford ALLOY 2209
d. Alternate materials must be submitted for approval prior to purchase.
2. Welding filler metals shall match the chemical composition and mechanical properties
of the base metals or shall be over alloyed.
3. All attachments such as brackets, supports and stiffeners shall be continuously welded
to prevent corrosion.
4. Welding shall not be performed during rain, snow, excessive wind, low temperature
and other adverse conditions unless a weather screen is erected to protect the welding
area and the welder. If conditions necessitate the removal of the weather screen
before the weld has cooled, a temporary covering shall be placed around the welded
joint.
5. The following additional requirements apply to 2205 duplex stainless steel welds:
a. No pre- or post-weld heat treatment shall be done for metallurgical reasons. If
ambient temperature is below 50°F or condensation is present, the base metal
should be warmed to a minimum of 80 °F (but no higher than 200 ºF) to ensure
the surface is dry.
b. Ignition of the electrode should always take place at a point within the joint
itself. Any striking scars alongside the joint shall be removed by grinding. Tack
welds should not be placed at the starting point for the root pass weld. If using
a wirefeed process under no circumstance shall unconsumed pieces of wire be
left within or on any portion of the weld zone.
c. Interpass temperature shall not exceed 300 °F (on the HAZ). Electronic
temperature probes and/or thermocouples shall be used to monitor the interpass
temperature.
d. Interpass Cleaning – All slag shall be removed between passes by wire brushing,
filing, chipping, or grinding to sound metal. All start and stop blemishes shall be
visually examined and shall be blended by grinding or filing when necessary to
assure proper fusion when welding over these areas. Grinding wheels shall not
have been used on any material other than stainless steel.
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e. Welds shall be deposited in straight stringer beads, with slight weave or
oscillation. Cover passes shall have a distinct crown (convex surface).
f. Autogenous welds are not permitted. GTAW wash passes, used for localized
smoothing, are prohibited. Repair welds performed using the GTAW method
require a separate welding procedure.
g. No more than two repair welds are permitted at a given location without prior
approval of the ENGINEER.
h. Finished welds and heat-affected zones (as well as the base metal) shall be free
from heat tint, discoloration, or any other surface contamination that can affect
the corrosion resistance.
i. Lifting attachments and temporary alignment and fit-up attachments for stainless
steel shall be from stainless steel of adequate strength. Lugs, guides and other
temporary attachments for weld fit-up shall be completely removed, leaving a
smooth stainless steel surface free of contamination.
2.5 IRON CASTINGS
A. All iron castings shall be of tough, close-grained, gray iron, free from blowholes, flaws or
excessive shrinkage and shall conform to current edition of ASTM A48 "Standard
Specifications for Gray Iron Castings, Class 40" having a minimum strength of 40,000 psi.
2.6 GENERAL DRIVE MECHANISM
A. Gear Design - The continuous output torque rating and the allowable stress values used in
the design of the intermediate worm gear reduction unit and the final gear reduction unit
shall be in conformance with the latest revision of the following standards:
1. Worm & Worm Gearing:
a. ANSI/AGMA 6034-B92, "Practice for Enclosed Cylindrical Worm gear Speed
Reducers and Gearmotors."
2. Spur and Pinion Gearing:
a. ANSI/AGMA 2001-C95, "Fundamental Rating Factors and Calculation Methods for
Involute Spur and Helical Gear Teeth."
3. The continuous output torque rating of the spur and pinion gearing shall be based on
the smaller of the rating values determined from the above ANSI/AGMA standard and a
design life of 20 years. The drive shall be designed and rated to develop the following
torque values based on a uniform sludge-loading rate of 13.5 lbs. (W) LB/FT.
Application Torque Foot-Pounds
Continuous Operating 30,000
Alarm Notice 30,000
Motor Shut-Off 36,000
Shear Pin Failure 45,000
Momentary Peak 60,000
4. The equipment manufacturer shall submit calculations to the ENGINEER for approval
substantiating the continuous output torque rating and design life. Calculations shall
include the spur gear, pinion, worm gear set, and all bearings used in the intermediate
worm gear reduction unit and the final gear reduction unit.
5. The spur gear and pinion calculations shall clearly specify the values used for the
following design parameters for surface durability and strength ratings:
a. Number of Pinions
b. Pinion Pitch Diameter
c. Actual Face Width
d. Tooth Diametrical Pitch
e. Tooth Geometry Factors (I and J Factors)
f. Hardness Ratio Factor
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g. Load Distribution Factor
h. Elastic Coefficient
i. Aspect Ratio
j. Life Factor
k. Allowable Contact Stress
l. Application Factor
m. Allowable Bending Stress
n. Rim Thickness Factor
6. Load distribution factors (Cm and Km) used in the calculations shall not exceed 1.28.
For parameters that are material dependent, such as allowable contact stress, the
calculations shall include a full description of the materials, quality grade, and heat
treatment used. Momentary peak torque calculations shall use a maximum of 75% of
yield strength.
B. Primary Gear Reduction Unit - The primary gear reduction unit shall consist of a totally
enclosed, horizontal type gearmotor or gear reducer with C-face mounted drive motor,
mounted on top of the intermediate worm gear housing. The primary gear reducer shall be a
heavy-duty parallel shaft helical type, conforming to ANSI/AGMA 6019-B89, and shall have a
service factor of 1.4, based upon the specified continuous running torque.
1. All gearbox bearings shall be of the anti-friction type and running in oil in a cast iron or
2205 duplex stainless steel housing. The totally enclosed primary reduction unit shall
operate on 3 phase, 60 hertz, 460 volt power source, and shall be at least 1 HP. The
motor shall conform to NEMA specifications for AC motors and be designed for
continuous operating in humid outdoor condition.
C. Chain Drive - Power transmission between the primary gear reduction unit and the
intermediate worm gear reduction unit shall be through an ASA 40 steel roller chain and steel
sprocket assembly. The chain drive shall be enclosed with a 316 stainless steel chain guard
meeting OSHA requirements. The shear pin overload shall be easily accessible by removal of
the chain guard.
D. Intermediate Worm Gear Reduction Unit - The intermediate worm gear reduction unit shall
consist of a worm gear driven by an integral straddle mounted worm and shaft, supported by
heavy duty anti-friction bearings running in an oil bath, and housing. Plain or sleeve type
bearings will not be acceptable. All bearings shall have a minimum L10 life of 20 years,
based on the continuous torque rating.
1. The integral worm and shaft shall be single piece and made from AISI 8620H alloy
steel carburized, hardened and ground and shall have a case hardness of 55-60 RC.
The worm gear shall be centrifugally cast, conforming to ASTM B271 and ANSI/AGMA
2004-B89, high strength, manganese bronze.
2. The worm gear shall have a Brinell hardness of 200 and have a minimum face width of
1.75 inches. The worm gear shall be keyed to the pinion shaft. The intermediate
worm gear housing shall be ASTM A48 Class 40 cast iron complete with seals, oil fill, oil
level sight gauge and drain plugs. The intermediate worm gear housing shall have full
360° contact and support from the final gear housing.
E. Final Gear Reduction Unit - The final gear reduction unit shall consist of a pinion, internal
spur gear, anti-friction ball bearing assembly, and a 2205 duplex stainless steel or cast
housing.
1. The pinion shall be AISI 4150 minimum grade 2 steel, heat-treated to a minimum 321
BHN hardness, have a minimum 6.00 inch pitch diameter and a have a minimum 3.06
inch face width.
2. The pinion shall be single piece, extending from the worm gear to the spur gear,
straddle mounted between anti-friction roller bearings to maintain accurate pinion to
spur gear alignment and contact. All bearings shall have a minimum L10 life of 20
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years based on the continuous torque. The pinion shall be manufactured to have a
minimum AGMA quality class 8, in conformance with ANSI/AGMA 2000-A88.
3. The internal spur gear shall be ductile iron normalized, quenched & tempered,
conforming to grade 120-90-02, with micro-structure of fine tempered pearlite,
conforming to ASTM A536, manufactured to have a minimum base hardness of 270
BHN and have a minimum AGMA quality Class 6, in conformance with ANSI/AGMA
2000-A88. The spur gear shall have a minimum 28-inch pitch diameter and have a
3.06 inch face width.
4. The internal spur gear shall be mounted on a large, full compliment anti-friction ball
bearing assembly designed to support the entire rotating clarifier mechanism.
5. The ball bearing assembly shall consist of a minimum 1” diameter AISI E52100 GRADE
50 chrome alloy steel bearing balls (60-64 RC) running in an oil bath protected from
contamination by a dust shield. The balls shall bear both horizontally and vertically on
four (4) renewable hardened alloy steel race liners inserted into the housing and the
internal spur gear. The minimum ball race diameter shall be 30 inches, to assure
stability. The race liner inserts shall be heat treated to a hardness of no greater than
39-43 RC to avoid fatigue cracking. The race liners and bearing balls shall be designed
for a minimum L10 life of 20 years.
6. The ball bearing assembly shall be mounted in an ASTM A48 Class 40 cast iron or 2205
duplex stainless steel housing. The housing shall be cast as a single piece to provide a
leak proof enclosure. The base of the housing shall be bolted to the top flange of the
stationary center column and designed to support the internal spur gear, the rotating
scrapper mechanism, and one end of the access bridge.
7. The housing shall be complete with seals, oil level gauge, oil fill, and valved oil and
condensation drains. A positive means of removing condensation and contaminant
from the lower pinion bearing pocket shall be provided.
8. Lubrication of the gear teeth shall be accomplished by means of an oil dam and the
meshing action of the pinion and the internal gear teeth that shall force lubricant up
the face of the teeth.
F. Overload Protection:
1. In addition to the shear pin protection the drive assembly shall include two (2) NEMA
IV limit switches located on the worm gear housing and operated by a spring loaded
actuator and aluminum pivot arm from the worm shaft. One (1) limit switch (N.O.)
contact is for alarm torque and one (1) limit switch (N.C.) contact is for cutout torque.
An aluminum pointer with aluminum graduated scale marked in 0, 25, 50, 75 and 100
percentages is provided for indicating load on drive at all times.
G. The complete spur gear drive assembly shall rotate the rake arm at a tip speed of
approximately 10 ft/min with the drive cage and rake arm assembly designed to withstand
approximately twice the design torque of the drive unit.
H. Drive Control Panel: The manufacturer of the sludge collector equipment shall provide a
local drive control panel mounted to the access bridge of the mechanism. The
interconnecting wiring and conduit shall be provided by the Contractor.
1. The drive control panel shall be a NEMA Size 1 combination starter with 3 leg thermal
overload protection and external reset, including a circuit breaker with flange mounted
visible disconnect switch, all in a NEMA 4X 316 stainless steel oversized enclosure.
Additional devices mounted within the enclosure shall include: a fused .5 KVA control
power transformer; overload relay, pending overload relay, and alarm silence relay;
and terminal strips for connecting the overload and alarm contacts located in the drive
torque monitor. External controls shall be weatherproof NEMA 4X corrosion resistant
and shall include: pull-to-start, push-to-stop, illuminated run switch; alarm silence
push-button; and, overload reset push-buttons. A weatherproof combination horn and
light fixture with 100 watt bulb shall be mounted to the top of the enclosure.
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2. The CONTRACTOR shall provide 3/60/460 volt power to the control panel and all
interconnecting wire and rigid conduit between the control panel and the torque
monitor mounted to the spur gear drive.
I. Alternative 2205 Duplex Stainless Steel Housing Drives:
1. The drive mechanisms shall be completely factory assembled and shall consist of a
motor, a gear reduction drive unit, fabricated 2205 duplex stainless steel base and gear
housing of seal welded construction, overload alarm, cutoff actuating system and shear
pin coupling. All gearing shall be enclosed in a fabricated 2205 duplex stainless steel
housing. All nuts, bolts, washers, anchor bolts, etc., shall be Type 316 stainless steel
for exposed service and Type 2205 duplex stainless steel for submerged service.
2. The drive unit shall consist of a solid internal main gear, turntable, pinion, secondary
helical speed reducer, support base, and drive unit bearing. The drive shall be
mounted on the center column and support the entire rotating load of the mechanism.
The main internal gear shall be forged of hardened steel. The pinion shall be heat
treated 8620 alloy steel core 300 BHN.
3. All speed reducers and main gearing shall be fully enclosed and running in grease.
Support base for the drive shall be of welded 2205 duplex stainless steel to assure
rigidity. Grease and dust shields shall be provided. The drive bearing shall include a
forged steel precision gear/bearing set, with fully contoured raceways hardened to a
minimum 58-60 RC. The main gear and pinion shall be oil or grease lubricated.
4. All bearings shall be anti-friction type. The precision gear/bearing set shall be one
piece design.
5. It shall turn the mechanism at the design collector output speed. The drive main
bearing shall be designed for the total rotating mechanism loads with a minimum L-10
life of 50 years or 438,000 operating hours. The drive unit shall be capable of
producing and withstanding the momentary peak torque while starting. The drive main
gear shall be designed to a minimum AGMA 6 rating when rated in accordance with
AGMA 2001-B88. The main bearing shall be capable of withstanding the listed
overturning moment without the aid of any underwater guides or bearings to ensure
correct tooth contact for AGMA rating of the main gear.
6. All gearing shall be designed per AGMA standard 2001-B88 for strength and surface
durability, based on a life of 175,000 hours. The main gear and pinion shall have a full
depth tooth form. Stub teeth shall not be acceptable. AGMA gear calculations must be
submitted. These must be certified by an independent gear consultant qualified in low
speed gearing. Induction hardened gears are not acceptable. The design running
torque rating of the drive gearing shall be based on the smaller of the two values
determined from the above AGMA standard. To ensure safety and ease of
maintenance, all components of the drive shall be direct coupled. No chains or sprock-
ets will be accepted.
7. No overhung pinions shall be allowed on the drive unit. The lower pinion bearing shall
not be located below the turntable base.
8. The drive and mechanism shall be manufactured by the same manufacturer for unit
responsibility. No third party drives will be accepted.
9. An overload device shall be provided in a Type 316 stainless steel, weatherproof
enclosure. The device shall be actuated by torque from the rotation of the secondary
speed reducer, which shall operate two independently adjustable switches (the alarm
switch at 100 percent of design running torque and the motor cutout switch at 120
percent of design running torque). These two switches shall be factory adjusted to
accurately calibrate the alarm torque value and the overload position. A visual torque
indicator shall be provided and oriented so that it may be read from the walkway. It
shall be calibrated from 0 to 160 percent of design running torque.
10. The turntable base shall have an annular bearing raceway upon which the rotating
assembly rests. It shall have a maximum allowable deflection in accordance with the
bearing specifications. The allowable modulus of elasticity shall be a minimum of 30 x
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106 psi. The center cage shall be fastened to and supported from the gear casing.
Ball bearings shall be of the highest quality high carbon chrome alloy steel running in
fully contoured races, as part of a precision gear/ bearing set. The balls shall be
grease lubricated and protected by elastomer seals. The bearing balls shall rotate in a
full circle four point contact raceway having a 60 degree contact angle for the transfer
of large thrust and overturning moment loading.
11. The allowable deflection for the bearing support base shall not exceed 0.006" under
full load. Calculations are required to verify deflection. The steel drive base shall
incorporate an annular chamber below the main gear to collect condensate. Minimum
depth shall be 3 1/2 inches. Annular cavity must be separate from lower pinion
bearing housing. Drive base must incorporate welded circular support rings to insure
stability. Designs using flat plates relying on plate thickness to resist deflection shall
not be allowed.
12. The speed reducing unit shall consist of helical or cycloidal speed reducer directly
connected to a motor without the use of chains or v-belts, and shall be keyed to the
pinion.
2.7 MOTORS
A. The motor shall be a 0.5 HP minimum, 1,800 rpm, squirrel cage, TEFC, induction type as
specified in Section 40 05 93, “Common Motor Requirements for Process Equipment”.
B. Motor shall be rated for continuous duty at nameplate rating meeting electrical standards per
NEMA publication MG1. Service factor shall be 1.15. The conduit box and output shaft end
shield/flange shall be Type 316 stainless steel. The motor stator shall be made of corrosion
resistant aluminum alloy (Silafont-13).
C. Power supply to the motor shall be 3/60/460 V.
2.8 CONTROLS
A. Furnish two (2) control panels, one for each secondary clarifier, as specified in Section 40 05
91, “Common Control Panel Requirements for Process Equipment”. Motor starters/controls
shall be housed in NEMA 4X, Type 316 stainless steel oversized enclosure. All controls
necessary for the fully automatic operation of the clarifier shall be provided. Refer to control
schematic in drawing for full requirements, at a minimum of the following shall be provided:
1. On-Off control switches for clarifier drive.
2. Single source power disconnect switch.
3. Power sensing overload protection device for each drive motor.
4. Green light indication clarifier operation on.
5. Red light indicating clarifier operation off.
6. Condensation panel heater with adjustable thermostat.
7. Audible alarm and flashing beacon for failure.
8. Provide contacts for remote monitoring of clarifier running, waring fail and on/off
switch station
9. High torque shutdown protection.
10. Elapsed Time Meters.
11. Provide fused sealed oversized control power transformer.
12. Provide NEMA rated size one (1) starter, conforming to electrical requirements for
across-the-line starters.
13. Provide engraved nameplates for each function.
14. Provide terminal strips in enclosure.
15. Submit control schematic and enclosure drawings with other required submittals.
16. Power Monitor, by Brunel Corporation #PTM-3-4X-L
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2.9 FEEDWELL
A. The feedwell shall be 28 feet minimum diameter and 7.5 feet minimum side depth supported
by structural members attached to the center rotating cage. The feedwell shall be fabricated
with flanged 2205 duplex stainless steel sheets segments with vertical flanges for field bolted
connections using 3/8” diameter fasteners. The top and bottom trim rings shall be minimum
3” x 3” x ¼” duplex stainless steel angles. The influent well shall be supported by and
rotated with the drive cage. Structural steel channels shall be provided to support the inlet
well. The feedwell shell shall be 3/16” PL minimum thickness.
2.10 ENERGY DISSIPATING INLET (BAFFLES)
A. The clarifier shall be equipped with an energy dispersion well or baffle system located inside
the rotating feedwell. This structure shall be designed to dissipate the energy of the
incoming flow by way of multiple baffled or inlet ports equally spaced around the dispersion
well.
B. This structure should promote effective mixing and tapered flocculation.
C. Flow shall impinge overlapping vertical target baffles/walls in secession with a series of
increasing port areas. Maximum baffle or port exit velocity shall be less than 0.15 fps at
peak influent flow.
D. Design to provide a "Gt" (t in seconds) value in the well not exceeding 5,000 with a velocity
gradient "G" within the well not exceeding 60 fps/ft at a minimum water temperature of 10
degrees-C at peak influent flow.
E. Provide horizontal shelf baffles to prevent downward movement in flocculation zone or the
well structure base will prevent this from occurring.
F. The bottom plate of the energy dissipating device shall be provided with properly sized drain
holes.
G. The Structure or Baffles shall bolt to center cage and feedwell support beams, thus rotate
with the mechanism.
H. EDI structural steel shall be a minimum of 3/16-inch thick.
I. Tub design EDI's will also be accepted.
J.
2.11 CENTER DRIVE CAGE
A. The center drive cage shall be provided with an attachment structure for the sludge collector
arms, and influent wells. The drive cage shall be completely supported and stabilized by the
main gear bearing. No below water supports, bearings or bumpers will be allowed.
B. The drive cage shall be of shop welded and field bolted connections.
2.12 SLUDGE COLLECTION
A. Scraper blades shall be designed for sufficient sludge transport capacity to handle the design
solids loading rate.
B. Sludge Rake Arms:
1. The mechanism shall include two long sludge rake arms of 2205 duplex stainless steel
truss construction and adjustable 2205 duplex stainless steel squeegees. The minimum
thickness of the structural steel shall be 1/4-inch.
2. Squeegees shall be fastened to the rake blades with 2205 duplex stainless steel
fasteners.
3. The mechanism shall be designed to sweep the entire tank floor twice on each
revolution.
4. The arms shall be adjustable at the cage to assure an even grout thickness over the
tank bottom.
5. The rake speed shall be sufficient to transport the necessary volume of sludge to the
sludge withdrawal pipes, but shall not re-suspend settled sludge.
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C. Sludge Withdrawal Pipes:
1. Withdrawal pipes shall extend from the rake arm mechanism up to a flanged
connection with the sludge collection trough. The pipes shall be as nearly straight and
vertical as possible, with a maximum deflection in any bend of 22.5 degrees.
2. To direct the sludge to each pipe, there shall be an additional blade opposite and
perpendicular to the rake arm. Alternatively, each blade can be in a “V” position to the
rake arm. One blade shall be included at each sludge withdrawal pipe.
3. Pipes shall be SCH. 10 Type 2205 duplex stainless steel.
4. Manufacturer shall design the sludge withdrawal pipes to be capable of collecting
sludge at the flow rates specified. The number of pipes on each rake arm shall be the
same and shall be located at the same points along the rake arm. Manufacturer is
responsible for locations of sludge withdrawal pipes to maximize sludge removal
efficiency.
D. Rotating Collection Troughs:
1. The open collection troughs provide for visual inspection of the return sludge flows
discharged from the sludge withdrawal pipes and for full surface skimming by means of
skimming weirs located at the liquid surface.
2. The trough shall permit easy access from the clarifier bridge for inspection and
cleaning of each sludge withdrawal pipe.
3. Two sludge collection troughs shall be provided per clarifier mechanism. The sludge
collection troughs shall be sized to induce and control the sludge flow from the suction
pipes and convey the sludge with minimal losses to the sight well. There shall be a
sludge collection box that the sludge discharges into. The sludge collection box shall be
supported from the rotating center drive cage. A neoprene seal shall be provided
between the collection box and center column.
4. The collection troughs shall by Type 2205 duplex stainless steel and extend from the
scum baffle to the center site well.
5. There shall be a minimum of three, 12-inch wide scum collection ports with adjustable
Type 2205 duplex stainless steel weir plates to collect surface scum from the scum
baffle to influent feedwell. Collected scum shall be removed along with the sludge. A
neoprene squeegee shall be provided between the scum baffle and collection trough.
2.13 CENTER PIER
A. Stationary Center Influent Column: A stationary Type 2205 duplex stainless steel cylindrical
influent column of ¼-inch minimum wall thickness shall be provided. One end shall have a
support flange for bolting to the tank floor, with a similar flange at the top for supporting the
drive unit and walkway. The structure and anchor bolts shall provide adequate support for
the entire mechanism dead load plus live load and torque with an adequate factor of safety
to eliminate excessive deflection or vibration.
B. Prior to the center column being plumbed and grouted in place, the drive unit shall be
installed, positioned, and leveled.
C. There shall be two sets of ports at the upper portion of the center pier. One set will open to
the center feedwell and assist in diffusing flow to reduce the inlet velocity. The other set of
ports shall convey sludge from the sludge collection box to the return sludge (RAS) outlet
pipe. The Manufacturer shall design and position the ports to optimize energy dissipation and
sludge removal efficiencies.
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D. A RAS pipe shall be installed concentric with the mixed liquor influent pipe. At 12 inches
above the finished floor, the RAS pipe shall penetrate through the influent pipe, center pier,
and tank foundation to connect with the existing RAS pipe. Manufacturer shall provide an
access port in the center pier to facilitate this connection. The RAS pipe arrangement as
shown on the drawings is based on Ovivo’s SRD device, patent No.: US 9,695,077 B2. Other
listed manufacturers shall submit to the Engineer for consideration, alternate means of
conveying the RAS down through the existing floor opening and to the existing under floor
RAS return pipe. Costs associated with alternate designs shall be borne by the Contractor. It
shall be the responsibility of the Manufacturer to provide a sealing arrangement with the
center pier, influent mixed liquor line, and the tank foundation to prevent intermixing of
mixed liquor and RAS flows.
2.14 SURFACE SCUM SKIMMING EQUIPMENT
A. General: The clarifier Manufacturer shall furnish two (2) skimming devices as part of each
clarifier mechanism. Each skimming mechanism shall be arranged to sweep the surface of
the clarifier and influent feedwell, automatically removing scum and floating material to a
scum box at the periphery of the tank or through the sludge collection troughs.
B. Surface skimming of the area within the scum baffles shall be accomplished by use the
sludge collection trough supported from and rotating with the drive cage and rake arms.
Three 12-inch overflow weirs shall be located on each sludge collection trough facing in the
direction of travel. One of the overflow weirs shall be located at the point of contact between
the inlet feedwell and sludge collection trough and a third overflow weir shall be located on
the 45-degree metered end of each trough near the inside of the scum baffles. Neoprene
squeegees shall be provided at the extremities of each trough for entrapment of scum by
positive contact with the inside of the scum baffle. The skimmings which overflow the six
12-inch weir sections on the clarifier shall be removed with the return sludge for further
processing. The remaining scum weirs shall be located at the mid-point of each trough.
C. Scum Box: The scum box shall be of the size specified, supported from the tank wall and
connected to the scum withdrawal piping. It shall be made of 1/4" thick welded steel plate.
The box shall have a scum trough, vertical steel sides, and a sloping approach ramp that
extends from 1/2" above water level to 6" below. A similar ramp shall be provided at the
opposite end to allow the skimmer blade to lower back to the operating position. A flexible
connector shall be provided for connection to the contractor supplied scum withdrawal piping
in the tank wall.
D. Scum Flushing Valve: A valve shall be attached to the scum box which automatically opens
and allows clarified liquid into the scum box to flush out solids. The valve shall actuate at
every pass of the scum skimmer over the scum box allowing sufficient delay after deposit of
the solids before flushing begins. Delay and flush duration shall be adjustable. The valve
shall be constructed of oil impregnated UHMW-PE disks with Type 2205 duplex stainless steel
rods and Type 2205 duplex stainless steel hardware. The opening and closing of the scum
flushing valve shall be one smooth continuous movement.
E. A 1-1/2" Schedule 80 PVC spray header shall be mounted on the bridge and shall direct scum
5
towards periphery using spray nozzles.
2.15 ANCHORAGE AND FASTERNERS
A. All equipment anchorage and fasteners, including bolts, nuts and washers shall be Type 316
stainless steel for exposed service and Type 2205 duplex stainless steel for submerged
service, furnished by the Manufacturer, and of ample size and strength for the purpose
intended, minimum of 1/2-inch diameter. All anchor bolts shall be set by the Contractor in
accordance with the Manufacturer's instructions. All templates required for setting the
anchorage shall be provided by the Manufacturer.
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2.16 FINISHES
A. Motor, gear box and appurtenances, etc., shall receive surface preparation, prime coating,
and finish coating in the factory prior to shipment in accordance with applicable requirements
of Section 09 91 00, “Painting and Protective Coatings”. Finish color shall be selected by the
OWNER during shop drawing review process. Submit color charts with shop drawings.
Furnish 1 gallon of touch up paint for installation contractor to apply.
2.17 SOURCE QUALITY CONTROL
A. Factory Tests and Adjustments: The equipment manufacturer shall perform a complete
factory testing procedure on the equipment to be installed. A report on the factory test
results is required prior to delivery of equipment to the jobsite. Test all pumping units and
controls to be furnished. Include test data sheets, curve test results, performance test logs,
certified by a factory test engineer.
B. Performance Test: Conduct on each unit under simulated operating conditions.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The equipment shall be erected by the CONTRACTOR and the erection work shall include
furnishing the necessary oil and grease for initial operation. "Initial operation" shall be
interpreted as meaning the first lubrication cycle beginning after all lubricants supplied by the
CONTRACTOR for start-up of the equipment are replaced. The grades of oil and grease
supplied by the CONTRACTOR shall be in accordance with the recommendations of the
equipment manufacturer.
B. Prior to submittal of shop drawings, field-verify existing center pier anchor locations and
determine new anchor bolt locations and sizes for existing clarifiers.
C. Install and adjust clarifier equipment in accordance with the Plans, approved shop drawings,
the manufacturer's instructions and the supplemental requirements included herein.
D. Do not cut or weld any galvanized steel component in the field. Violation of this requirement
will result in rejection of affected components.
3.2 FIELD QUALITY CONTROL
A. Functional Tests: Conduct on each unit as described below and in accordance with Section 01
75 25 “Equipment Testing and Startup.”
1. Alignment: Test complete assemblies for correct rotation, proper alignment and
connection, and quiet operation.
2. Performance Test: Place each piece of equipment in the system in operation until the
entire system is functioning. All components shall continue to operate without alarms
or shut downs, except as intended, for eight consecutive hours to be considered
started up. Operate the equipment through the design performance range consistent
with available flows. Adjust, balance, and calibrate and verify that the equipment,
safety devices, controls, and process system operate within the design conditions.
Each safety device shall be tested for proper setting and signal. Response shall be
checked for each equipment item and alarm. Simulation signals may be used to check
equipment and alarm responses.
3. Sludge collector mechanisms shall be field tested after erection in the presence of the
ENGINEER.
a. Verify structural and mechanical compliance by loading each collector mechanism
to the alarm and shut-off torque settings.
b. Test operation of warning and shut down circuits.
4. Test Procedures:
a. Testing accomplished with machine in operation.
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b. Apply loads to truss arms by means of cables or other means anchored to tank
floor or wall.
c. Loads are to be applied by means of a hydraulic cylinder or springs or any means
which allows the machine to rotate over a minimum of 3 feet peripheral distance
under load.
5. A copy of all information from functional tests, including data, worksheets, and other
materials shall be turned over to the OWNER at the completion of the testing program.
3.3 MANUFACTURER’S SERVICES
A. MANUFACTURER’s services shall comply with the requirements of Section 01 75 25,
“Equipment Testing and Facility Startup. Training shall comply with the requirements of
Section 01 79 00, “Demonstration and Training.”
B. Provide the following services.
1. The MANUFACTURER shall furnish a qualified field representative for a minimum of two
(2) working days to inspect all equipment described herein after installation, to assist in
troubleshooting, to advise the CONTRACTOR and OWNER during startup and testing,
and to instruct OWNER's personnel in routine maintenance and troubleshooting
procedures. This period shall consist of a minimum of an 8-hour day and travel to and
from the project site shall be the responsibility and at the cost of the MANUFACTURER.
2. Field representatives shall have a minimum of two (2) years of experience with the
operation of and training on this type of equipment. Factory-employed personnel will
be required to perform this service. Sales representatives will only be considered
acceptable service technicians if they have three (3) years of experience with the
operation of and training on this type of equipment from the manufacturer being
supplied and have started up 15 units of a similar size and type from the manufacturer.
3. Two training sessions shall be performed, one in the early morning and one in the late
afternoon. CONTRACTOR shall coordinate the scheduling of such training and start-up
assistance with OWNER'S personnel. OWNER may videotape training session. A typed
outline shall be handed out at the training sessions and, at a minimum, will include
normal operating parameters, alarms, and maintenance.
3.4 STARTUP PREPARATION
A. Complete equipment installation with controls, safety devices and auxiliary support systems
necessary to start the equipment and verify that the equipment functions correctly under no
load conditions. Turn rotating equipment by hand to check. Complete cleaning and testing
of piping systems. Inspect and clean equipment, devices, piping, and structures of debris
and foreign material.
B. Remove temporary bracing supports and other construction debris that may damage
equipment.
C. Remove protective coatings and oils used for protection during shipment and installation.
D. Flush, fill, and grease lubricated systems in accordance with MANUFACTURER's instructions.
E. Install temporary connections and devices required to fill, operate, checkout and drain the
system. Provide temporary valves, gauges, piping, test equipment, and other materials and
equipment necessary to conduct testing and startup.
F. Check equipment for correct direction of rotation and freedom of moving parts.
G. Align equipment to MANUFACTURER's tolerances. Adjust clearances and torques.
H. Check installation prior to start-up for conformance to MANUFACTURER's instructions.
I. Adjust or modify equipment to ensure proper operation.
J. Correct any deficiencies or problems noted in MANUFACTURER's representative's installation
reports.
PLUMMER ASSOCIATES, INC. 46 43 21 - Page 18 of 20 BID SET
0537-038-01 CIRCULAR CLARIFIER EQUIPMENT JANUARY 2023
3.5 START UP AND FINAL ACCEPTANCE
A. Startup of the facility shall be in accordance with Section 01 75 25, “Equipment Testing and
Startup.” At the end of the above specified period of operation, the equipment will be
accepted if, in the opinion of the ENGINEER, the equipment has operated satisfactorily
without excessive power input, wear, lubrication, or undue attention required for this
operation, and if all rotating parts operate without excessive vibration or noise at any
operating speed and head, including shutoff.
B. MANUFACTURER's installation report and complete and Final Operation & Maintenance
Manuals are required prior to final acceptance.
END OF SECTION
PLUMMER ASSOCIATES, INC. 46 43 21 - Page 19 of 20 BID SET
0537-038-01 CIRCULAR CLARIFIER EQUIPMENT JANUARY 2023
PLUMMER ASSOCIATES, INC. 46 43 21 - Page 20 of 20 BID SET
0537-038-01 CIRCULAR CLARIFIER EQUIPMENT JANUARY 2023
F:\\PROJECTS\\0537\\038-01\\9 DESIGN\\9-4 SPECIFICATIONS\\CONFORMED\\46 43 21 CIRCULAR CLARIFIER EQUIPMENT_V2.DOCX
APPENDIX 1
GEOTECHNICAL REPORT
PAGE IS INTENTIONALLY LEFT BLANK
• GEOTECHNICAL ENGINEERING
• MATERIALS ENGINEERING & TESTING
• SOILS • ASPHALT • CONCRETE
GEOTECHNICAL SUBSURFACE INVESTIGATION AND RECOMMENDATIONS
FOR THE PROPOSED
BROADWAY WWTP REHABILITATION (18084A)
1402 W BROADWAY STREET
CORPUS CHRISTI, TEXAS
MSA NO. 3399, PROJECT NO. 18084A, TASK ORDER NO. 15
RETL REPORT NUMBER: G121393
PREPARED FOR:
CITY OF CORPUS CHRISTI
ENGINEERING SERVICES
4917 HOLLY ROAD BLDG. 2
CORPUS CHRISTI, TEXAS 78411
SEPTEMBER 23, 2021
PREPARED BY:
ROCK ENGINEERING & TESTING LABORATORY, INC.
6817 LEOPARD STREET
CORPUS CHRISTI, TEXAS 78409
P: (361) 883-4555; F: (361) 883-4711
TBPE FIRM NO. 2101
ROCK ENGINEERING & TESTING LABORATORY, INC.
Corpus Christi San Antonio Round Rock
Office: 361.883.4555 Office: 210.495.8000 Office: 512.284.8022
Fax: 361.883.4711 Fax: 210.495.8015 Fax: 512.284.7764
6817 Leopard St. 10856 Vandale 7 Roundville Ln.
Corpus Christi, TX 78409 San Antonio, TX 78216 Round Rock, TX 78664
www.rocktesting.com
GEOTECHNICAL ENGINEERING
CONSTRUCTION MATERIALS
ENGINEERING & TESTING
SOILS ASPHALT CONCRETE
September 23, 2021
City of Corpus Christi-Engineering Services
4917 Holly Road Bldg. 2
Corpus Christi, Texas 78411
Attention: Ms. Sandra L. Gomez, P.E.
SUBJECT:SUBSURFACEINVESTIGATION, LABORATORY TESTING PROGRAM, AND
FOUNDATION RECOMMENDATIONS
FOR THE PROPOSED
BROADWAY WWTP REHABILITATION (18084A)
1402 W Broadway Street
Corpus Christi, Texas
MSA No. 3399, Project No. 18084A, Task Order No. 15
RETL Job No. –G121393
Dear Ms. Gomez,
In accordance with our agreement, we have conducted a subsurface investigation, laboratory
testing program,and foundation evaluation for the above referenced project. The results of
this investigation, together with our recommendations, are to be found in the accompanying
report, one electronic copy of which is being transmitted for your records and for distribution to
the project design team.
Often, because of design and construction details that occur on a project, questions arise
concerning soil conditions and Rock Engineering and Testing Laboratory, Inc. (RETL) (TBPE
Firm No. 2101), would be pleased to continue its role as the Geotechnical Engineer during
project implementation.
RETL also has great interest in providing materials testing and observation services during the
construction phase of this project.If you will advise us of the appropriate time to discuss these
engineering services, we will be pleased to meet with you at your convenience.
Sincerely,
Mark C. Rock, P.E.
Senior Consultant
ROCK ENGINEERING & TESTING LABORATORY, INC.
Corpus ChristiSan AntonioRound Rock
Office: 361.883.4555Office: 210.495.8000Office: 512.284.8022
Fax: 361.883.4711Fax: 210.495.8015Fax: 512.284.7764
6817 Leopard St.10856 Vandale7 Roundville Ln.
Corpus Christi, TX 78409San Antonio, TX 78216Round Rock, TX 78664
www.rocktesting.com
SUBSURFACE INVESTIGATION, LABORATORY TESTING PROGRAM, AND
FOUNDATION RECOMMENDATIONS
FOR THE PROPOSED
BROADWAY WWTP REHABILITATION (18084A)
1402 W BROADWAY STREET
CORPUS CHRISTI, TEXAS
MSA NO. 3399, PROJECT NO. 18084A, TASK ORDER NO. 15
RETL JOB NUMBER: G121393
PREPARED FOR:
CITY OF CORPUS CHRISTI
ENGINEERING SERVICES
4917 HOLLY ROAD BLDG. 2
CORPUS CHRISTI, TEXAS 78411
SEPTEMBER 23, 2021
PREPARED BY:
ROCK ENGINEERING AND TESTING LABORATORY, INC.
6817 LEOPARD STREET
CORPUS CHRISTI, TEXAS 78409
PHONE: (361) 883-4555; FAX: (361) 883-4711
TEXAS PROFESSIONAL ENGINEERING FIRM
REGISTRATION NO. 2101
James P. Bauer, P.E.Francisco J. Arias, P.E.
Corpus Christi Branch ManagerSenior ProjectEngineer
TABLE OF CONTENTS
Page
INTRODUCTION ...................................................................................................................................................................... 1
Authorization .........................................................................................................................................................................
1
Purpose and Scope .............................................................................................................................................................. 1
General .................................................................................................................................................................................
1
SITE DESCRIPTION ................................................................................................................................................................ 2
FIELD EXPLORATION ............................................................................................................................................................ 2
Scope ...................................................................................................................................................................................
2
Drilling and Sampling Procedures ......................................................................................................................................... 3
Field Observations ................................................................................................................................................................ 3
LABORATORY TESTING PROGRAM .................................................................................................................................... 5
SUBSURFACE CONDITIONS ................................................................................................................................................. 5
General .................................................................................................................................................................................
5
Soil Conditions ......................................................................................................................................................................
6
Groundwater Observations ................................................................................................................................................... 7
OSHA Soil Type Classification .............................................................................................................................................. 8
Seismic Site Classification .................................................................................................................................................... 9
FOUNDATION DISCUSSION................................................................................................................................................... 9
Project Description ................................................................................................................................................................ 9
PVR Discussion .................................................................................................................................................................... 9
FOUNDATION TYPES CONSIDERED .................................................................................................................................. 10
FOUNDATION RECOMMENDATIONS ................................................................................................................................. 11
Slab-on-Grade Foundation Recommendations ................................................................................................................... 11
Ground Improvement .......................................................................................................................................................... 13
Straight Shaft Drilled Pier Foundation Recommendations .................................................................................................. 13
Lateral Pier Analysis ........................................................................................................................................................... 15
Below Grade Walls ............................................................................................................................................................. 15
Small Above Grade Walls ................................................................................................................................................... 16
SITE IMPROVEMENT METHODS ......................................................................................................................................... 16
Drainage and Flatwork Construction Considerations .......................................................................................................... 16
CONSTRUCTION CONSIDERATIONS ................................................................................................................................. 17
Site Preparation .................................................................................................................................................................. 17
Structural Reinforced Select Fill .......................................................................................................................................... 18
Drilled, Cast-in-Place Piers ................................................................................................................................................. 18
Earthwork and Foundation Acceptance .............................................................................................................................. 19
Utilities ................................................................................................................................................................................
19
GENERAL COMMENTS ........................................................................................................................................................ 19
APPENDIX:
Site Vicinity Map
Boring Location Plan
Boring Logs OCEP-1, SEP-1, HA-1, HA-2, HA-3, B-7(2008)
Key to Soil Classification and Symbols
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
INTRODUCTION
This report presents the results of a soil exploration and foundation analysis for the proposed
Broadway Wastewater Treatment Plant (WWTP) Rehabilitation project planned for the existing
WWTP located at 402 W Broadway Street, in Corpus Christi, Texas.
Authorization
The scope of work for this project was performed in accordance with Rock Engineering and
Testing Laboratory, Inc. (RETL) Proposal No.CGP062821A (Revision 1) dated July 23, 2021.
The scope of work and fee was approved on August 2, 2021, by issuance of Task Order No.
15 under the Master Service Agreement (MSA) for Geotech and Construction Materials Testing
– Rock, Contract No. 3399. The Task Order was delivered to RETL via email transmission.
Purpose and Scope
The purpose of this exploration was to evaluate the soil and groundwater conditions at the site
and to provide foundation recommendations suitable for the proposed Broadway WWTP
Rehabilitation project. The scope of the exploration and analysis included the subsurface
exploration, field and laboratory testing, engineering analysis and evaluation of the subsurface
soils, provision of foundation recommendations, and preparation of this report
The scope of services did not include an environmental assessment. Any statements in this
report, or on the boring logs, regarding odors, colors, unusual or suspicious items or conditions
are strictly for the information of the client.
General
The exploration and analysis of the subsurface conditions reported herein are considered
sufficient in detail and scope to provide foundation recommendations for the proposed project.
The information submitted in this report is based on project details provided by the City of
Corpus Christi and the soil information obtained at the boring locations. If the designers require
additional soil parameters to complete the design of the proposed foundation system and this
information can be obtained from the soil data and laboratory tests performed within the scope
of work included in our proposal for this project, then RETL will provide the additional
information requested as a supplement to this report.
The Geotechnical Engineer states that the findings, recommendations, specifications or
professional advice contained herein have been presented after being prepared in a manner
consistent with that level of care and skill ordinarily exercised by reputable members of the
Geotechnical Engineer’s profession practicing contemporaneously under similar conditions in
the locality of the project. RETL operates in general accordance with “Standard Practice for
Minimum Requirements for Agencies Engaged in the Testing and/or Inspection of Soil and
Rock as Used in Engineering Design and Construction, (ASTM D3740)”. No other
representations are expressed or implied, and no warranty or guarantee is included or
intended. This study was conducted for the City of Corpus Christi and the design team for the
specific application to the proposed Broadway WWTP Rehabilitation project in Corpus Christi,
Texas.
Page 1 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
SITE DESCRIPTION
The site for the proposed Broadway Wastewater Treatment Plant (WWTP) Rehabilitation
project is composed of three areas within the existing WWTP located at 402 W Broadway
Street, in Corpus Christi, Texas. The general location of the planned rehabilitation
improvements is shown on the Site Vicinity Plan included in the Appendix and discussed below
in further detail.
Area 1: Northwest corner of the plant near the existing Resaca Lift Station where a new
Odor Control System is planned.
Area 2: Northwest of the existing Aeration Basins where a new Septage Dump Station
is planned.
Area 3: Northeast corner of the existing Aeration Basin #4 where an Elevated Effluent
Trough is planned to be connected to the existing aeration basin.
The site areas during the time of our field exploration were grass covered and relatively flat
and level. As an exception, approximately 6 inches of gravel was encountered at the surface
in two borings performed in Area 3. Owner coordination was required to access the plant. At
the time of our field investigation the condition of the ground surface was firm and did not pose
any difficulties to the drill crew moving their equipment.
FIELD EXPLORATION
Scope
The field exploration to evaluate the engineering characteristics of the foundation bearing
materials included reconnaissance of the project site, performing the test boring operations and
obtaining disturbed split spoon and grab soil samples. During the sample recovery operations
the soils encountered were classified and recorded on the boring logs in accordance with
“Standard Guide for Field Logging of Subsurface Exploration of Soil and Rock, (ASTM D5434).”
Five (5) borings were performed for the purpose of providing geotechnical recommendations
for the proposed project. In addition, one boring previously drilled by RETL in 2008 (Job
G108122) was used to estimate soil properties near the Elevated Effluent Trough. The table
below provides the boring identification, boring depths and GPS coordinates.
Summary of Boring Information
Boring ID Boring Depth (ft) Proposed Structure GPS Coordinates
OCEP-1 25 Odor Control System N 27.80469° W 97.40220°
SEP-1 25 Septage Dump Station N 27.80525° W 97.40170°
HA-1 5 N 27.80523° W 97.40108°
HA-2 7 N 27.80508° W 97.40105°
Elevated Effluent
Trough
HA-3 3 N 27.80498° W 97.40104°
B-07* 50 N 27.80518° W 97.40103°
*Boring B-07 previously drilled on 01/18/08 for RETL Project G108122. GPS coordinates for this boring location estimated
based on boring location shown on site plan associated with previous report in 2008.
Page 2 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
RETL determined the number, depth and location of the borings based on project information
provided and discussion with the project design team, prior to issuance of RETL proposal
CGP062821A (Revision 1). RETL performed the drilling, hand augering and sampling. The
GPS coordinates were obtained at the boring locations using a Garmin GPS model eTrex and
are provided in this report and on the boring logs.
Upon completion of the field exploration and obtaining the groundwater observations, the
borings were backfilled with excess soils obtained during drilling operations. A Boring Location
Plan is provided in the Appendix of this report.
The borings performed for this project were used to determine the classification and strengths
of the subgrade soils. The information provided on the boring logs includes boring location,
boring depth, soil classification, soil strengths, and laboratory test results. The boring logs are
included in the Appendix.
Drilling and Sampling Procedures
Borings OCEP-1 and SEP-1 were performed using a drilling rig equipped with a rotary head
turning hollow stem augers to advance the boreholes. Disturbed soil samples were obtained
employing split-barrel sampling procedures in general accordance with the procedures for
“Penetration Test and Split-Barrel Sampling of Soils, (ASTM D1586).”
Borings HA-1, HA-2 and HA-3 were advance using a hand auger and grab samples were
obtained at select intervals. The hand auger and sampling operations were performed in
accordance with the procedures for “Standard Practice for Soil Exploration and Sampling by
Auger Borings, (ASTM D1452).” These borings were terminated upon encountering subsurface
conditions, such as shallow groundwater or gravelly/sandy soils, in which the hand augering
could not be advanced.
The samples from the borings listed above were visually classified, placed in plastic bags,
marked according to boring number, depth and any other pertinent field data, stored in special
containers and delivered to the laboratory for testing.
Field Observations
Penetration Tests – During the sampling procedures, standard penetration tests (SPT) were
performed to obtain the standard penetration value of the soil at selected intervals. The
standard penetration value (N) is defined as the number of blows of a 140-pound hammer,
falling 30 inches, required to advance the split-barrel sampler 1 foot into the soil. The sampler
is lowered to the bottom of the previously cleaned drill hole and advanced by blows from the
hammer. The number of blows is recorded for each of three successive 6-inch penetrations.
The “N” value is obtained by adding the second and third 6-inch increment number of blows.
An automatic hammer was utilized when performing SPT. An automatic hammer is usually
taken as having an efficiency of one. The results of standard penetration tests indicate the
relative density of cohesionless soils and comparative consistency of cohesive soils, thereby
providing a basis for estimating the relative strength and compressibility of the soil profile
components.
Page 3 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Static Cone Penetrometer Tests – Portable static cone penetrometer tests were performed
at select depths within the borings performed using hand augers, typically at each sample
interval and at the boring termination depth. The portable static cone penetrometer is a device
used for measuring soil consistency and is equipped with dual rods enabling the cone stress
to be measured directly. Soil friction on the outer rod does not influence the reading. The cone
is forced into the soil in increments and retracted slightly after each increment to zero the
gauge, and then the cone is advanced to obtain the cone index (Qc). The cone index is always
22
read directly from the gauge. It has units of kg/cm, which is essentially equal to tons/ft. The
results of the portable static cone penetrometer tests are provided on their respective boring
logs using the notation Qc.
The correlation between the cone index and soil constants is not absolute. The following
empirical formulas were provided by the portable static cone penetrometer manufacturer, Boart
Longyear Company, and have been determined through extensive field use of the unit:
1. Standard Penetration Test Value “N”
N = Qc/4
2. Unconfined Compressive Strength “Qu” (tsf)
Uniform clay and silty clays: Qu = Qc/5
Clayey silts: Qu = Qc/(10 to 20)
3. Cohesion “C” or Undrained Shear Strength (tsf)
Uniform clay and silty clays: C = Qc/10
Clayey silts: C = Qc/(20 to 40)
Water Level Observations – Water level observations were obtained during the test boring
operations. Water level observations are noted on the boring logs provided in the Appendix.
In relatively pervious soils, such as sandy soils, the indicated depths are usually reliable
groundwater levels. In relatively impervious soils, such as clayey soils, a suitable estimate of
the groundwater depth may not be possible, even after several days of observation. Seasonal
variations, temperature, land-use, proximity to water bodies and recent rainfall conditions may
influence the depth to the groundwater. The amount of water in open boreholes largely
depends on the permeability of the soils encountered at the boring locations.
Ground Surface Elevations – The ground surface elevation at the boring locations were not
provided, therefore, depths referred to in this report are from the ground surface at the boring
locations during the time of our field investigation.
Page 4 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
LABORATORY TESTING PROGRAM
In addition to the field investigation, a laboratory testing program was conducted to determine
additional pertinent engineering characteristics of the subsurface materials necessary in
analyzing the behavior of the foundation system for the proposed project.
The laboratory testing program included supplementary visual classification (ASTM D2487)
and water content tests (ASTM D2216) on the samples. In addition, selected samples were
subjected to Atterberg limits tests (ASTM D4318) and percent material finer than the #200 sieve
tests (ASTM D1140). The laboratory testing program was conducted in general accordance
with applicable ASTM Specifications. The results of these tests are to be found on the
accompanying boring logs provided in the Appendix.
SUBSURFACE CONDITIONS
General
The types of foundation bearing materials encountered in the test borings have been visually
classified and are described in detail on the boring logs. The results of the standard penetration
tests, static cone penetrometer tests, water level observations and laboratory tests are
presented on the boring logs. Representative samples of the soils were placed in polyethylene
bags and are now stored in the laboratory for further analysis, if desired. Unless notified to the
contrary, the samples will be disposed of three months after issuance of this report.
The stratification of the soil, as shown on the boring logs, represent the soil conditions at the
actual boring locations. Variations may occur and should be expected beyond or between the
boring locations. Lines of demarcation represent the approximate boundary between different
soil types, but the transition may be gradual, or not clearly defined.
It should be noted that, whereas the test borings were drilled and sampled by experienced
drillers, it is sometimes difficult to record changes in stratification within narrow limits. In the
absence of foreign substances, it is also difficult to distinguish between discolored soils and
clean soil fill.
Page 5 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Soil Conditions
The generalized soil conditions encountered at the project site have been summarized and soil
properties including soil classification, strength, and plasticity are provided in the following
tables.
Soil Profile Table – Boring OCEP-1
D Description LL PI C -#200 N
e
0-3 FILL: Clayey SAND 27 14 1,000 -- 110 36 10
Sandy Lean CLAY and Fat CLAY
3-8 62 42 250 -- 110 81 2-3
with sand
8-10.5 Fat CLAY with Sand -- -- 125 -- 50 -- WOH
10.5-14 Silty SAND 36 21 -- 28 50 28 2
13-18 Sandy Lean CLAY -- -- 250 -- 55 -- 3
18-25 Poorly Graded SAND with Silt -- -- -- 29 50 9 6-7
Soil Profile Table – Boring SEP-1
D Description LL PI C -#200 N
e
0-6 Clayey SAND 40 25 250 -- 110 38 1-4
6-10 Fat CLAY with Sand 80 54 125 -- 115 81 WOH
10-18 Silty SAND NP NP -- 28 50 19 2-3
18-23 Lean CLAY with Sand -- -- 600 -- 55 71 5
23-25 Poorly Graded SAND with Silt -- -- -- 29 50 -- 7
Page 6 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Soil Profile Table – Borings HA-1 to HA-3 and B-07(2008)
D Description LL PI C -#200 Qc N
e
FILL: Sandy Lean CLAY,
0.5-5 35-42 21-27 900 -- 115 35-62 7-17 --
CLAYEY Sand and Fat CLAY
FILL: Sandy Lean CLAY,
5-8 35-42 21-27 450 -- 55 37-56 5-50 --
CLAYEY Sand
8-12 Silty Clayey SAND -- -- -- 28 50 14 -- 2-5
12-18 Fat CLAY -- -- 250 -- 55 -- -- 2
18-23 Fat CLAY 101 71 2,000 -- 60 99 -- --
23-28 Poorly Graded SAND -- -- -- 29 50 -- -- 6
Poorly Graded SAND, Silty
28-47 -- -- -- 32 55 3-4 -- 14-30
Clayey SAND
47-50 Fat CLAY -- -- 3,000 -- 60 89 -- --
*Borings HA-1, HA-2 and HA-3 were terminated upon hand auger refusal at depths of 3 to 7 feet.
Where:
D = Depth in feet below existing grade
LL = Liquid limit (%)
PI = Plasticity Index
C = Soil Cohesion, psf (undrained)
= Angle of Internal Friction, deg. (undrained)
= Effective soil unit weight, pcf
e
-#200 = Material passing #200 sieve, %
N = Standard Penetration Test (blows per foot)
WOH = Weight of Hammer
Qc = Cone Index (TSF)
Exceptions to the above generalized soil profiles due exist. Detailed descriptions of the soils
encountered at the boring locations are provided on the boring logs included in the Appendix.
Groundwater Observations
Groundwater (GW) observations and the depths the borings caved are provided in the following
table.
Groundwater (GW) Observations
Boring During Drilling Upon Completion Delayed Readings
OCEP-1 10 feet GW at 9 feet and Caved at 13 feet --
GW at 7 feet and Caved at 13 feet
SEP-1 13 feet GW at 10 feet and Caved at 14 feet
(3-Hour Delayed Reading)
HA-1 5 feet GW and Caved at 5 feet --
HA-2 5 feet GW at 5 feet and Caved at 5½ feet --
HA-3* Not Encountered Not Encountered --
B-7 6 feet GW at 8 feet and Caved at 14 feet GW at 5 feet and Caved at 9 feet
*Boring HA-3 was terminated at a depth of 3 feet.
Page 7 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Based on observations made in the field, groundwater at the site was encountered at depths
between 5 and 13 feet. It should be noted that the water level in open boreholes may require
several hours to several days to stabilize depending on the permeability of the soils and that
groundwater levels at this site may be subject to seasonal conditions, recent rainfall, tidal
fluctuations, drought or temperature effects. We recommend that the contractor verifies the
groundwater table before construction and be prepared to implement dewatering
techniques as required.
OSHA Soil Type Classification
The table below provides a summary of the OSHA Soil Type Classification based on the soils
encountered at the boring locations.
Depth OSHA SOIL TYPE
DESCRIPTION
(feet) CLASSIFICATION
0-5 Undocumented Fill and Granular Soil (Sand) above Groundwater Type C
5-20 Submerged Soil (Sand and Clay) Type C
It should be noted that the contractor’s “competent person” shall make the final determination
of the OSHA Soil Type during excavation of the soils at the jobsite. Slope protection for
excavations greater than 20 feet need to be designed and sealed by a professional engineer
registered in the State of Texas. The maximum allowable slopes during construction for soil
OSHA soil types are provided in the following table.
Guidelines for Maximum Allowable Slopes
Soil or Rock Type Max. Allow. Slopes for Excavations < Than 20’ Deep
Stable Rock Vertical
Type A ¾ Horizontal : 1 Vertical
Type B 1 Horizontal : 1 Vertical
Type C 1½ Horizontal : 1 Vertical
Guidelines for maximum allowable slopes were obtained from OSHA documents, but do not
consider any recent revisions or the stability of long-term unprotected slopes, which will likely
require much flatter slopes. The guidelines presented herein for slopes do not imply RETL is
taking responsibility for construction site safety; this responsibility falls entirely upon the
contractor and his responsible person. RETL is assuming that the contractor will comply with
all rules, ordinances and other requirements to conform with safe construction practices.
Page 8 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Seismic Site Classification
In accordance with the International Building Code (IBC), “When the soil properties are not
known in sufficient detail to determine the site class, Site Class D shall be used unless it is
determined that Site Class E or F soil is likely to be present at the site.” Since our field
investigations have not included a 100-foot deep boring, by definition the soil properties are not
known in sufficient detail. Site Class E soils should have a Standard Penetration Resistance
of less than 15 bpf and an undrained shear strength of less than 1,000 pounds per square foot
(psf). The predominant soil strengths at this site generally meet the typical strength range cited
above and therefore the site should be classified as Seismic Site Class E.
FOUNDATION DISCUSSION
Project Description
Based on information provided to RETL, the project will consist of multiple improvements for
the existing Broadway WWTP in Corpus Christi, Texas. The planned improvements include a
new Odor Control System, new Septage Dump Station and adding a new Elevated Effluent
Trough to the northeast wall of Aeration Basin #4. We understand that the Odor and Septage
improvements are planned to be supported on shallow foundations, whereas the Elevated
Effluent Trough will likely be supported on deep foundations. In addition, above and below
grade retaining structures are planned for the project. The location of these proposed
structures is shown in the Site Vicinity Plan included in the Appendix.
PVR Discussion
The laboratory test results indicate that the subsoils in the active zone at this site are medium
to high in plasticity. The total potential vertical rise (PVR) was calculated at the location of the
structures proposed for the project. A summary of the calculated PVR is presented in the table
below.
Summary of PVR Calculations
Boring ID Structure/Location Estimated PVR (inch)
OCEP-1 Odor Control System 1½ to 2
SEP-1 Septage Dump Station 2¾ to 3¼
HA-1, HA-2, HA-3, B-07* Elevated Effluent Trough 1 to 1½
*From RETL Job G108122.
The PVR values summarized in the table represent the vertical rise that can be experienced
by dry subsoils if they are subjected to conditions that allow them to become saturated, such
as poor drainage. The actual movement of the subsoils is dependent upon their change in
moisture content.
Page 9 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
The PVR calculations were performed using the Texas Department of Transportation Method
TEX-124E and considered the depth of the active zone, estimated to extend to a depth of
approximately 10 feet at this site, and the Atterberg limits test results of the soils encountered
within the active zone. Differential vertical movements at this site may be equal to the
calculated PVR over a distance equal to the depth of the active zone if dry soil conditions exist
and a localized water source such as ponding water or a plumbing leak occurs resulting in non-
uniform moisture conditions.
Undercutting a portion of the natural expansive soils at this site and replacing them with
properly compacted “Structural Reinforced Select Fill” to construct the foundation pads
should reduce the PVR. The resulting reduction in PVR at this site, utilizing undercutting and
replacement operations, are included in the table below. The estimated PVR values provided
are based on the foundation applying a sustained surcharge load of approximately 1.0 pound
per square inch on the subgrade soils. It should be noted that although some of the previously
calculated PVR values are relatively low, undercut depths deeper than typical are required to
extend below the depths of the relatively shallow low PI soils to remove the deeper high
expansive clay soils in order to improve the PVR and increase bearing capacity.
PVR Reduction
Minimum “Structural
Required Undercut Depth (ft)
Boring ID Structure/Location Reinforced Select Fill”
for 1-inch PVR
Thickness (ft)
OCEP-1 Odor Control System 5 6
SEP-1 Septage Dump Station 5 6
HA-1, HA-2, HA-Elevated Effluent
1½ 2½
3, B-7 Trough
Upon completion of the excavations, as listed above, to reduce the PVR to approximately 1
inch, the exposed subgrade soils shall be moisture conditioned and recompacted in place, and
“Structural Reinforced Select Fill” should be properly placed and compacted in the
excavation to construct the foundation pads.
FOUNDATION TYPES CONSIDERED
Various foundation types have been considered for the support of the proposed structures for
this project. The foundation types considered include shallow and deep foundations.
Stiffened Slab-on-Grade Foundation – A stiffened grid type beam and slab foundation is
used to support relatively light structures where the soil conditions are relatively uniform, and
where uplift and settlement can be tolerated. The intent of a stiffened slab-on-grade foundation
is to allow the structure and foundation to move freely with soil movements while providing
sufficient stiffness to limit differential movements. This type of foundation is acceptable for the
support of the structures for the Odor Control System and the Septage Dump Station, provided
that the site improvement earthwork recommendations included in the “PVR Discussion”,
“Site Preparation” and “Foundation Recommendations” sections of this report are
performed.
Page 10 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Due to the near surface low strength soils at the locations of the Odor Control System and
Septage Dump Station, a shallow slab-on-grade foundation will provide relatively low bearing
capacities. An increase in capacity for the support of shallow slab-on-grade foundations may
be possible by constructing the foundation pads with “Structural Reinforced Select Fill”, as
indicated before. If additional bearing capacity is required, it is recommended to implement
ground improvement techniques such as installing rammed aggregate piers or soil modulus
columns to further enhance the soils, as discussed in the “Ground Improvement” section of
this report.
Conventional Footings and Mat Foundations – Conventional footings and mat foundations
were considered for the support of the planned structures. Due to the relatively low strengths
of the near surface soils and underlying loose sands, as well as the presence of existing surface
fills, these foundations are not recommended for the support of the structures due to the
potential for differential movement from both settlement and the potential volume change of the
surface soils. In addition, these foundation types typically have a wider contact pressure area
which results in an increase in stress deeper in the soil profile. As groundwater is relatively
shallow, dewatering and shoring would be required to allow for excavation of low strength soils
which extend to the depths of at least 18 to 20 feet; therefore, additional excavation extending
below the groundwater table is likely cost prohibitive. RETL should be contact if it desired to
explore this option in more detail.
Drilled Piers – A deep foundation system consisting of conventional straight shaft drilled piers
is suitable for the support of the Elevated Effluent Trough. The utilization of underreamed piers
is not recommended due to the low strength of the soils and the relatively shallow depth of the
groundwater. Furthermore, the construction of straight shaft piers will require the utilization of
temporary casing, the slurry drilling method, or a combination of casing and the slurry method
to stabilize the pier excavations and prevent sloughing of the weak soils into the pier excavation
prior to pier observation, placement of reinforcing steel and concrete pouring.
Recommendations for a stiffened slab-on-grade foundation for the support of the Odor Control
and Septage structures, and straight-shaft drilled pier foundations for the support of the Effluent
Trough are provided in this report. If it essential to demand the highest level of performance
from the Odor Control and Septage structures foundations, then RETL recommends utilizing a
deep foundation system in conjunction with a structural floor slab. If this is the case RETL
should be contacted to provide additional recommendations.
FOUNDATION RECOMMENDATIONS
Slab-on-Grade Foundation Recommendations
Monolithic stiffened grid type beam and slab-on-grade foundations are feasible to support the
proposed structures for the Odor Control System and the Septage Dump Station, if foundation
movements of approximately 1 inch can be tolerated. The PVR shall be reduced to
approximately 1 inch by performing the recommended site improvements in the “PVR
Discussion” and “Site Preparation” sections of this report.
Page 11 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Interior and exterior grade beams should be founded within the foundation pad constructed
with “Structural Reinforced Select Fill”, bearing at a minimum depth of 2 or 2½ feet,
respectively, below the finished floor slab elevation. The beams can be designed considering
the allowable bearing capacities listed below, which include an approximate design safety
factor of 3.
Allowable Bearing Capacity For Slab-on-Grade Foundations
Location Allowable Bearing Capacity
Odor Control System 1,200 psf
Septage Dump Station 750 psf
Concentrated loads should be placed at widened grade beam locations, at intersection of grade
beams or where haunches can be constructed if loading conditions warrant increased bearing
area. The beams should be a minimum of 12 inches wide to reduce the potential for localized
shear failure and should be spaced at a maximum distance of 17 feet, in both directions. The
width of the beams should not exceed 24 inches to avoid deeper stress propagation. The
Structural Engineer may vary beam depths and spacing based on experience designing and
constructing similar type structures on sites with similar subsurface soil conditions.
The “Design of Slab-On-Ground Foundations,” published by the Wire Reinforcement Institute,
Inc. (Aug., 1981), utilizes the design criteria provided in the table below:
WRI Design Criteria
Climatic Rating (Cw) 17
Effective Plasticity Index 30
Soil/Climatic Rating Factor (1-C) 0.15
Maximum Beam Spacing, Both Directions (ft) 17
WRI slab design criteria provided above considers that excavation of the existing soils, organics
and other deleterious materials are removed to the depths required to reduce the PVR and
increase bearing capacity as previously discussed. This excavation needs to be extended
laterally at least 5 feet beyond the footprint of the foundations and any appurtenances.
Immediately after excavation, the exposed subgrade soils should be moisture conditioned and
compacted. Once the subgrade has been compacted the foundation pad should be
constructed by replacing the excavated soils with properly compacted “Structural Reinforced
Select Fill” as further detailed in the “Construction Considerations” section of this report.
Slab-on-Grade Foundations designed as recommended could expect total and differential
settlements ton the order of 1 and ½ inch, respectively.
Page 12 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Ground Improvement
In order to further increase the bearing capacity of shallow foundations, consideration could be
given to utilizing deeper soil improvement techniques such as the installation of rammed
aggregate piers, stone columns or rigid inclusion systems. These techniques can substantially
improve the strength and compressibility of the weak soils and/or transfer load through them
to deeper more competent layers, enhancing significatively the bearing capacity of shallow
foundation systems. These methods of ground improvement are performed through the
services of a specialty design/install contractor and the ground improvement can be designed
and performed to obtain predefined performance specifications, thereby modifying the site to
enable construction of standard or prototypical shallow foundations. These specifications are
presented below.
For this project the recommended performance specifications for ground improvement are as
follows:
1. Bearing Capacity. The net allowable bearing capacity (considering a minimum
Safety Factor of 3.0) for shallow foundations must be at least 2,500 pounds for
square foot (psf).
2. Settlement. Considering short-term (elastic) settlement, long-term (consolidation)
settlement and secondary compression (creep) of the soil, the maximum total and
differential settlement for shallow foundation systems must be 1 inch and ½ inch,
respectively.
3. Modulus of Subgrade Reaction (k). The minimum modulus of subgrade reaction
p
for the design of mat foundations must be at least 175 pounds per cubic inch (pci).
If different values than those listed above are required for the project, the performance
specifications should be amended accordingly. If ground improvement is selected for
this project, the performance specifications should be communicated to the specialty
contractors so they can design the ground improvements to comply with them.
Straight Shaft Drilled Pier Foundation Recommendations
A deep foundation system consisting of conventional straight shaft drilled piers is the
recommended foundation system for the Elevated Effluent Trough. The structural designer
can utilize the allowable unit skin friction values for the range in depths included in the following
table for straight shaft drilled piers (including micro-piles) to resist the axial loads given the
strengths of the subsurface soils encountered.
Page 13 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Allowable Unit Skin Friction Values
Depth Below Existing Grade (ft) Allowable Unit Skin Friction (psf)
0-8 Neglect
8-18 90
18-23 500
23-28 300
28-45 500
All depths are referenced from the existing ground surface elevations at the boring locations
during the time of our field investigation.
The allowable unit skin friction values provided above are based on the strengths of the in-situ
soils and utilize a design safety factor of 2 against shear failure. The straight shaft drilled piers
should be founded at depths between 15 and 45 feet.
The piers will be subject to uplift forces resulting from adhesion of the expansive soils along
the perimeter of the shafts. This uplift force can be estimated (in kips) by multiplying the
diameter of the pier (in feet) by 10. Uplift can be resisted utilizing the dead load on the pier
and the weight of the pier itself. If additional resistance to expansive soil induced uplift is
required, the allowable skin friction values below a depth of 10 feet may be utilized in the
design. Uplift due to structural loading conditions can utilize the allowable skin friction values
provided in the table above.
Settlement of a properly designed and constructed straight shaft drilled pier is estimated to be
on the order of 1 percent of the shaft diameter of the pier and differential settlements of equally
loaded same size drilled shafts should experience differential settlements on the order of ½
percent of the pier shaft diameters.
Straight shaft drilled piers should be spaced no closer than three pier diameters apart
measured center to center. Drilled piers at this site should be adequately reinforced with a
minimum of 1 percent of the cross-sectional area of the pier shaft throughout the depth of the
pier to withstand uplift forces.
Page 14 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Lateral Pier Analysis
Drilled piers may be subjected to lateral loads. Lateral pier analysis programs such as L-pile
will require the following soil parameters for this site.
L-Pile Design Criteria
D Description C K E
50
e
0-8 UNDOCUMENTED CLAY FILL Neglect
8-12 SAND -- 28 50 20 --
12-18 CLAY 250 -- 55 30 0.020
18-23 CLAY 2,000 -- 60 500 0.007
23-28 SAND -- 29 50 20 --
28-45 SAND -- 32 55 60 --
Where: D = depth (ft)
C = shear strength, psf
= effective unit weight, pcf
= angle of internal friction, deg.
K = modulus of subgrade reaction (pci)
E = 50% strain value
50
K and E values were estimated from known correlations.
50
Below Grade Walls
Below grade walls constructed for the project will act as retaining wall structures. Retaining
walls must be designed to resist the loads imposed by the retained soil and any surcharge
loads.
Equivalent fluid density values for active and at rest conditions were evaluated for various
backfill materials. These values for different acceptable backfill soils and their respective USCS
soil classification symbols are presented in the table below.
Equivalent Fluid Density (pcf)
Backfill Material
Active At Rest
Clayey Fill
65 85
(PI=15 to 25)
Sand (SP, SM or SM-SP)
45 65
(PI < 7)
Free Draining Gravel
35 55
(GW, GP or GM)
Page 15 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Retaining walls which are allowed to move slightly will develop an “active” earth pressure
condition. If the wall is restrained from lateral movements such as when it is part of a fixed
structure, the “at rest” earth pressure condition will be developed.
It is very important to note that in designing below grade wall structures, the equivalent fluid
densities in the table above DO NOT include the effect of surcharge loads due to adjacent
structures, equipment, vehicular loads or future storage near the walls. These items should be
a sufficient distance from the walls such that surcharge loads are not placed on the below grade
walls or must be properly accounted for in the design.
In addition, where the fill materials will be located below the groundwater elevation, and where
there is a possibility for submergence, the pressures on the walls shall include the
hydrostatic pressure.
Backfill for retaining walls shall be compacted to a minimum density of 95 percent of the
maximum dry density as determined by the standard Proctor (ASTM D698) and the moisture
content shall be maintained at or above the optimum moisture content.
All compaction operations shall be performed in an attempt to minimize stress on the below
grade walls. Compaction operations for each lift of fill soils shall begin at the wall and work
back away from the wall in an effort to reduce the pressures on the wall due to construction
activities.
Small Above Grade Walls
Small above grade retaining walls (less the 4-feet in height) planned for the project may be
designed using the equivalent fluid densities and recommendations presented in the preceding
section for “Below Grade Walls”. The allowable bearing capacity for the design of small
above grade retaining walls is 200 psf, provided they are founded on a 3-foot thick foundation
pad constructed with “Structural Reinforced Select Fill” as indicated before, and the width of
the wall footing does not exceed 3 feet. If taller walls are required or additional bearing capacity
is required, then RETL should be contacted and provided with specific details.
SITE IMPROVEMENT METHODS
Drainage and Flatwork Construction Considerations
The change in moisture content of the plastic clay soils is the primary mechanism resulting in
the volumetric changes of the supporting soils. Provisions in the site development should be
made in order to maintain relatively uniform moisture contents of the supporting soils. A
number of measures may be used to attain a reduction in subsoil moisture content variations,
thus reducing the soil’s shrink/swell volume change potential. Some of these measures are
outlined below.
During construction, positive drainage schemes should be implemented to prevent
ponding of water on the subgrade.
Page 16 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Positive grades sloping away from the foundations and flatwork should be designed and
implemented. We recommend that effective site drainage plans be devised by others prior
to commencement of construction to provide positive drainage away from the site
improvements, both during, and after construction.
Where any below grade utilities are installed, the top 2 feet of utility trenches should be
backfilled with low plasticity clays to assure the trenches do not serve as aqueducts that
could transport water beneath the structure and flatwork due to excessive surface water
infiltration. Clay plugs or collars should also be installed in utility trenches, from outside of
the building pad and extending several feet beneath the structure, to prevent water from
moving laterally into the select fill pad and beneath the foundation.
All efforts should be made to avoid having situations where site flatwork panels are
partially supported on properly compacted select fill soils and partially supported on
natural in-situ highly plastic soils which will result in differential movement and may also
result in a negative slope back to the foundations.
If associated flatwork will be constructed, and if it is desired to reduce the PVR movements
beneath flatwork, the expansive soils should be undercut and replaced with select fill as
discussed in the “PVR Discussion” and “Site Preparation” sections of this report.
All project features beyond the scope of those discussed above should be planned and
designed similarly to attain a region of relatively uniform moisture content within the foundation
and flatwork areas. Poor drainage schemes are generally the primary cause of foundation and
flatwork problems on clay soils.
CONSTRUCTION CONSIDERATIONS
Site Preparation
If a shallow stiffened slab-on-grade foundation will be used, the upper plastic clayey soils
should be excavated (undercut) to the depths indicted before in the “PVR Discussion” section
of this report to reduce the PVR to 1 inch. Once the excavation operations in the foundation
area are performed, the upper 1 foot of exposed subgrade soils shall be compacted to a
minimum density of 95 percent of the maximum dry density as determined by the standard
Proctor test (ASTM D698) and the moisture content shall be maintained at or above the
optimum moisture content. If any soft areas are identified, the soils should be removed and
recompacted in place. The excavated soils should be replaced with properly compacted
“Structural Reinforced Select Fill” to construct the foundation pads and increase the bearing
capacity of shallow foundations.
Page 17 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
Structural Reinforced Select Fill
Imported select fill material used at this project to construct the foundation pads should consist
of TxDOT Item 247 Crushed Limestone, Type A or B, Grade 1-2 or 3, and should be reinforced
with layers of Tensar™ Geogrid TX-160. The purpose of the geogrid is to reinforce the
foundation pads to increase bearing capacity, increase the stiffness of the pad, and reduce
differential settlement for the shallow foundation systems proposed. The first layer of geogrid
should be placed atop the previously moisture conditioned and compacted exposed subgrade
at the bottom of the excavation performed to reduce PVR to 1 inch. Additional layers of geogrid
should be placed at a rate of 1 layer for each 12-inches of compacted select fill placed. The
uppermost geogrid layer should be placed within 1 foot from the bottom of the grade beams.
The geogrid layers should be placed following manufacturer’s recommendations.
The select fill should be placed in loose lifts no thicker than 8 inches and properly compacted
to a minimum density of 95 percent of the maximum dry density, as determined by the standard
Proctor test (ASTM D698), and at or above the optimum moisture content.
Drilled, Cast-in-Place Piers
Successful installation of straight shaft drilled piers at this site, particularly below the
groundwater elevation at the time of construction, will require temporary steel casing or the
slurry drilling method (or a combination of both methods) to prevent sloughing soils from
entering the pier excavation prior to pier observation, placing reinforcing steel and pier
concrete. Steel casing may be used for piers no deeper than 20 feet, and will require
“sealing” the casing into the upper clay layer found in Boring B-07. It is recommended to install
the casing 2 to 3 feet (but no more than 3 feet) below the tip of the piers. The foundation
contractor should be prepared and shall have casing on-site in the event that it is necessary.
The excavation for piers deeper than 20 feet will need to be stabilized with the slurry method,
as a deeper competent clay layer to seal the casing is not present until a depth of approximately
50 feet.
Drilled piers constructed utilizing temporary steel casing require that the concrete be placed as
soon as possible after all loose material has been removed, the pier excavation inspected, and
reinforcing steel installed. A relatively high slump concrete mix (6 to 7 inches) is suggested to
minimize aggregate segregation caused by the reinforcing steel. Free fall of concrete into the
pier excavation is permitted provided the concrete can be placed into the pier excavation
without striking the sides of the excavation or hitting the rebar.
It should be noted that research has shown that free fall concrete guided at the top of the
excavation to avoid contact with the sides of the pier excavation and reinforcing steel can drop
more than 80 feet without any measurable segregation. In addition, the research has shown
that as long as the concrete drop is in air the strength of the concrete was not adversely
affected. In situations where it is impossible for the concrete to fall freely without striking the
rebar cage or sides of the pier excavation the free fall should be limited to 10 feet, or placed
with a tremie. Pier excavations should not be allowed to stay open overnight.
Page 18 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
The successful placement of a pier foundation is dependent on the expertise of the drilled pier
foundation contractor. It is recommended that test piers be performed at the site at the time of
construction to verify groundwater conditions at the specific location and time, and to ensure
that the proper method of pier installation is being performed. The Geotechnical Engineer, or
his designated representative, should be present to witness the pier excavation and installation
of all production piers.
Earthwork and Foundation Acceptance
Exposure to the environment may weaken the soils at the foundation bearing level if the
excavations remain open for long periods of time. Therefore, it is recommended that the
foundation excavations be extended to final grade and that the foundation be constructed as
soon as possible to minimize potential damage to the bearing soils. The foundation bearing
levels should be free of loose soil, ponded water or debris and should be observed prior to
concreting by the Geotechnical Engineer, or his designated representative.
Foundation concrete should not be placed on soils that have been disturbed by rainfall or
seepage. If the bearing soils are softened by surface water intrusion, or by desiccation, the
unsuitable soils must be removed from the foundation excavations and be replaced with
properly compacted fill prior to placement of concrete per Engineer’s direction.
The Geotechnical Engineer, or his designated representative, should monitor subgrade
preparation and placement of fill. As a guideline, a minimum of one, in-place density test shall
be performed on the subgrade soils and each subsequent lift of fill for each 3,000 square feet,
or a minimum of three in-place density tests per testing interval, whichever is greater. Any
areas not meeting the required compaction should be recompacted and retested until
compliance is met.
Utilities
Utilities that project through or are connected to the foundation systems should be designed
with either some degree of flexibility, or with sleeves, in order to prevent damage to these lines
should vertical movement occur.
GENERAL COMMENTS
If significant changes are made in the character or location of the proposed structures, a
consultation should be arranged to review any changes with respect to the prevailing soil
conditions. At that time, it may be necessary to submit supplementary recommendations.
It is recommended that the services of RETL be engaged to test and evaluate the soils in the
foundation excavations prior to concreting in order to verify that the bearing soils are consistent
with those encountered in the borings. RETL cannot accept any responsibility for any
conditions that deviate from those described in this report, nor for the performance of the
foundation if not engaged to also provide construction observation and testing for this project.
If it is required for RETL to accept any liability, then RETL must agree with the plans and
perform such observation during construction as we recommend.
Page 19 of 20
September 23, 2021 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393 MSA No. 3399, Project No. 18084A, Task Order No. 15
All sheeting, shoring, dewatering and bracing of trenches, pits and excavations should be made
the responsibility of the contractor and should comply with all current and applicable local, state
and federal safety codes, regulations and practices, including the Occupational Safety and
Health Administration.
Page 20 of 20
APPENDIX
GEOTECHNICAL ENGINEERING
CONSTRUCTION MATERIALS
ENGINEERING & TESTING
SOILS ASPHALT CONCRETE
SITE VICINITY MAP
New Septage
Dump Station
Stabilization of the
Elevated Effluent
New Odor
Trough
Control System
SITE
September 23, 2021 BROADWAY WWTP REHABILITATION(18084A)
Attn: Ms. Sandra L. Gomez, P.E.402 W Broadway Street
RETL Job Number G121393Corpus Christi, Texas
ROCK ENGINEERING & TESTING LABORATORY, INC.
Corpus ChristiSan AntonioRound Rock
Office: 361.883.4555Office: 210.495.8000Office: 512.284.8022
Fax: 361.883.4711Fax: 210.495.8015Fax: 512.284.7764
6817 Leopard St.10856 Vandale7 Roundville Ln.
Corpus Christi, TX 78409San Antonio, TX 78216Round Rock, TX 78664
www.rocktesting.com
GEOTECHNICAL ENGINEERING
CONSTRUCTION MATERIALS
ENGINEERING & TESTING
SOILS ASPHALT CONCRETE
BORING LOCATION PLAN
September 23, 2021 BROADWAY WWTP REHABILITATION(18084A)
Attn: Ms. Sandra L. Gomez, P.E.402 W Broadway Street
RETL Job Number G121393Corpus Christi, Texas
ROCK ENGINEERING & TESTING LABORATORY, INC.
Corpus ChristiSan AntonioRound Rock
Office: 361.883.4555Office: 210.495.8000Office: 512.284.8022
Fax: 361.883.4711Fax: 210.495.8015Fax: 512.284.7764
6817 Leopard St.10856 Vandale7 Roundville Ln.
Corpus Christi, TX 78409San Antonio, TX 78216Round Rock, TX 78664
www.rocktesting.com
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!!
GEOTECHNICAL ENGINEERING
CONSTRUCTION MATERIALS
ENGINEERING & TESTING
SOILS ASPHALT CONCRETE
March 22, 2022
City of Corpus Christi - Engineering Services
4917 Holly Road Bldg. 2
Corpus Christi, Texas 78411
Attention: Ms. Sandra L. Gomez, P.E.
SUBJECT: GEOTECHNICAL SUPPLEMENT NO. 1
SUBSURFACE INVESTIGATION, LABORATORY TESTING PROGRAM, AND
ADDITIONAL FOUNDATION RECOMMENDATIONS
FOR THE PROPOSED
BROADWAY WWTP REHABILITATION (18084A)
1402 W Broadway Street
Corpus Christi, Texas
MSA No. 3399, Project No. 18084A, Task Order No. 15
RETL Job No. – G121393SA1
Dear Ms. Gomez,
Rock Engineering and Testing Laboratory, Inc. (RETL) is providing this Geotechnical
Supplement No. 1 for the referenced project. Supplement No. 1 provides additional deep
foundation recommendations for use by the team in designing the foundations for
supporting the proposed Septage Dump Station, Odor Control Equipment, and Elevated
Effluent Trough structures.
RETL previously provided recommendations for the project in a report dated September 23,
2021. We were recently informed that deep foundations are being considered for
supporting the structures of the project. In order to obtain soil data to depths sufficient for
designing deep foundations, we remobilized a drill rig to the site and drilled three (3) deeper
borings at or near the locations of the proposed structures. In addition, the information from
previous borings drilled at the site in 2008 and 2021 was also analyzed.
A summary of the new drilled borings is presented in the table below:
ROCK ENGINEERING & TESTING LABORATORY, INC.
Corpus Christi San Antonio Round Rock
Office: 361.883.4555 Office: 210.495.8000 Office: 512.284.8022
Fax: 361.883.4711 Fax: 210.495.8015 Fax: 512.284.7764
6817 Leopard St. 10856 Vandale 7 Roundville Ln.
Corpus Christi, TX 78409 San Antonio, TX 78216 Round Rock, TX 78664
www.rocktesting.com
March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393SA1 MSA No. 3399, Project No. 18084A, Task Order No. 15
Summary of Boring Information
Boring ID Boring Depth (ft) Proposed Structure Approximate GPS Coordinates
B-1A EET 55 Elevated Effluent Trough N 27.80526° W 97.40105°
B-2A SEP 50 Septage Dump Station N 27.80526° W 97.40173°
B-3A OCS 50 Odor Control System N 27.80470° W 97.40219°
The location of the new and previously drilled borings is shown on attached Boring Location
Plan.
Additional recommendations for deep foundations based upon the field and laboratory data
obtained during the recent supplemental investigation and previous investigations are
provided in this Geotechnical Supplement No.1. Any recommendations contained within
our original report and not specifically addressed herein shall remain unchanged.
Soil Conditions
The soil conditions encountered at the boring locations have been summarized and soil
properties including soil classification, undrained shear strength, angle of internal friction,
and effective unit weight are provided in the following tables.
Soil Profile Table (Elevated Effluent Trough) – Boring B-1A EET, B-7(2008) & HA-1 thru HA-3
D Description LL PI C -#200 N P
e
FILL: CLAYEY Sand,
0-6 25-42 12-27 500 -- 115 20-62 3-6 --
Sandy Lean CLAY
Silty SAND, Poorly
6-9 Graded SAND with 33 19 -- 28 50 9-37 1-2 --
Silt, Clayey SAND
Lean CLAY with
9-11 42 26 150 -- 55 71 1 --
Sand,
Silty SAND, Silty
11-17 -- -- -- 28 50 14-29 2-5 --
Clayey SAND
Sandy Fat CLAY,
17-23 101 71 250 -- 55 67-99 2 3.0
Fat CLAY
Poorly Graded SAND,
Poorly Graded SAND
23-37 -- -- -- 32 55 2-4 6-30 --
with Silt and Gravel,
Silty Clayey SAND
Poorly Graded SAND,
37-47 Poorly Graded SAND -- -- -- 36 55 3-5 14-46 --
with Silt and Gravel
47-55 Fat CLAY -- -- 3,000 -- 60 89-100 -- 4.0-4.5+
*It should be noted that the near surface soils within the upper 20 feet varies between Borings B-1A, B-7(2008) and HA-1 through HA-3.
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March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393SA1 MSA No. 3399, Project No. 18084A, Task Order No. 15
Soil Profile Table (Septage Dump Station) – Boring B-2A SEP & SEP-1 (2021)
D Description LL PI C -#200 N P
e
0-4 CLAYEY Sand 22-40 8-25 500 -- 115 38-44 4 --
Poorly Graded SAND
4-5.5 -- -- -- 28 110 10 1-4 --
with Silt
Sandy Lean CLAY,
5.5-10.5 27-80 13-54 125 -- 115 53-81 WOH-1 --
Fat CLAY with SAND
10.5-17 Silty SAND NP NP -- 28 50 19 2-3 --
Sandy Lean CLAY,
17-22 3622 500 -- 55 58-71 4-5 --
Lean CLAY with Sand
Poorly Graded SAND
22-32 -- -- -- 34 55 7 7-33 --
with Silt
Poorly Graded SAND
32-34 -- -- -- 33 55 -- 17 --
with Silt
34-37 Lean CLAY with Sand -- -- 2,000 -- 60 -- 17 --
Poorly Graded SAND
37-42 -- -- -- 33 55 10 17 --
with Silt
42-50 Fat CLAY -- -- 3,000 -- 60 96 -- 4.25-4.5
Soil Profile Table (Odor Control System) – Boring B-3A OCS & OCEP-1 (2021)
D Description LL PI C -#200 N P
e
POSSIBLE FILL:
0-3 27 14 1,000 -- 115 36 10-13 --
CLAYEY Sand
POSSIBLE FILL:
3-5.5 CLAYEY Sand, Sandy 24 10 250 -- 110 22 2-7 --
Lean CLAY
Sandy Lean CLAY,
5.5-8 62 42 400 -- 110 81 3-4 --
Fat CLAY with Sand
Sandy Lean CLAY,
8-10.5 47 29 125 -- 115 66 WOH --
Fat CLAY with Sand
10.5-13 Silty SAND 36 21 -- 28 50 28 2 --
13-17 Sandy Lean CLAY -- -- 250 -- 55 63 1-3
Poorly Graded SAND
17-27 with Silt, Poorly -- -- -- 29 50 2-9 4-7 --
Graded SAND
27-32 Poorly Graded SAND -- -- -- 36 55 -- 28 --
32-34 Silty SAND -- -- -- 30 55 15 12 --
32-37 CLAYEY Sand 44 29 1,500 -- 55 33 12 --
37-48 Silty SAND -- -- -- 29 50 16 3-13 --
48-50 Fat CLAY -- -- 3,000 -- 60 96 -- 4.5+
3 of 8
March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393SA1 MSA No. 3399, Project No. 18084A, Task Order No. 15
Where:
D = Depth in feet below existing grade
LL = Liquid limit (%)
PI = Plasticity Index
C = Soil Cohesion, psf (undrained)
= Angle of Internal Friction, deg. (undrained)
= Effective soil unit weight, pcf
e
-#200 = Material passing #200 sieve, %
N = Standard Penetration Test (blows per foot)
WOH = Weight of Hammer
P = Hand Penetrometer (TSF)
Detailed descriptions of the soils encountered at the boring locations are provided on
attached boring logs.
Drilled Piers
Recommendations provided herein are applicable to straight shaft drilled piers. The
structural designer can utilize the allowable unit skin friction values for the range in depths
included in the following tables to resist the axial loads.
Allowable Unit Skin Friction Values - Elevated Effluent Trough
Boring B-1A EET, B-7(2008) & HA-1 thru HA-3
Depth Below Existing Grade (ft) Allowable Unit Skin Friction (psf)
0-5 Neglect
5-11 50
11-17 100
17-23 75
23-37 275
37-47 575
47-50 700
Allowable Unit Skin Friction Values - Septage Dump Station
Boring B-2A SEP & SEP-1 (2021)
Depth Below Existing Grade (ft) Allowable Unit Skin Friction (psf)
0-5 Neglect
5-10 50
10-17 100
17-22 175
22-37 550
37-45 650
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March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393SA1 MSA No. 3399, Project No. 18084A, Task Order No. 15
Allowable Unit Skin Friction Values - Odor Control System
Boring B-3A OCS & OCEP-1 (2021)
Depth Below Existing Grade (ft) Allowable Unit Skin Friction (psf)
0-5 Neglect
5-11 50
11-17 100
17-27 200
27-32 600
32-45 500
All depths are referenced from the existing ground surface elevations at the boring
locations during the time of our field investigation.
The allowable unit skin friction values provided above are based on the strengths of the in-
situ soils and utilize a design safety factor of 2 against shear failure. The straight shaft
drilled piers should be proportioned to be founded at depths between 20 feet and the
maximum depths listed in the tables above.
The piers will be subject to swell uplift forces resulting from adhesion of the expansive soils
along the perimeter of the shafts. The swell uplift force can be estimated (in kips) by
multiplying the diameter of the pier (in feet) by 5. Uplift can be resisted utilizing the dead
load on the pier and the buoyant weight of the pier itself. If additional resistance to
expansive soil induced uplift is required, the allowable skin friction values below a depth of
10 feet may be utilized in the design. Uplift resistance due to structural loading conditions
can be calculated by utilizing 60 percent of the allowable skin friction values provided in the
tables above.
Properly designed and constructed straight shaft drilled piers can be expected to experience
settlement on the order of 1 percent of the shaft diameter of the pier and differential
settlements of equally loaded same size drilled shafts should experience differential
settlements on the order of ½ percent of the pier shaft diameter.
Drilled piers at this site should be adequately reinforced with a minimum of 1 percent of the
cross-sectional area of the pier shaft throughout the depth of the pier to withstand uplift
forces.
We recommend utilizing structural suspended floor slabs in conjunction with the
drilled pier foundations.
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March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393SA1 MSA No. 3399, Project No. 18084A, Task Order No. 15
Group Effect on Deep Foundations
Drilled piers should be spaced no closer than three pier diameters apart measured center to
center, to avoid bearing capacity reductions for closely spaced piers. If groups of piers are
required to support concentrated loads, an appropriate modification of the estimated bearing
capacity must be made on the basis of the group efficiency factor.
The supporting capacity of a group of vertically loaded drilled piers can be considerably less
than the sum of capacities of the individual members comprising the group. The capacity of
the group varies as a function of change in size, spacing and stiffness. Axial group capacity
may be estimated from the following:
P = E * N * Q
Where E is the group efficiency, N is the number of piers in the group and Q is the single
drilled pier capacity. Values of group efficiency E increase from about 0.8 at a pier spacing
of 2.5 to about 1.0 at a spacing of 5 pier diameters. Detailed analyses of pier-soil
interaction for a specific group spacing would be necessary to define actual efficiency.
Lateral Pier Analysis
Lateral pier analysis programs such as L-pile will require the following soil parameters for
this site:
L-Pile Design Criteria - Elevated Effluent Trough
Boring B-1A EET, B-7(2008) & HA-1 thru HA-3
D Description C K E
s50
e
0-5 CLAY Neglect
5-9 SAND -- 28 50 20 --
9-11 CLAY 150 -- 55 30 0.020
11-17 SAND -- 28 50 20 --
17-23 CLAY 250 -- 55 30 0.020
23-37 SAND -- 32 55 60 --
37-47 SAND -- 36 55 60 --
47-50 CLAY 3,000 -- 60 1,000 0.005
6 of 8
March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E. 402 W Broadway Street, Corpus Christi, Texas
RETL Job Number G121393SA1 MSA No. 3399, Project No. 18084A, Task Order No. 15
L-Pile Design Criteria - Septage Dump Station
Boring B-2A SEP & SEP-1 (2021)
D Description C K E
s50
e
0-5 CLAY/SAND Neglect
5-10.5 CLAY 125 -- 115 30 0.020
10.5-17 SAND -- 28 50 20 --
17-22 CLAY 500 -- 55 30 0.020
22-32 SAND -- 34 55 60 --
32-34 SAND -- 33 55 60 --
34-37 CLAY 2,000 --- 60 1,000 0.005
37-42 SAND -- 33 55 60 --
42-45 CLAY 3,000 -- 60 1,000 0.005
L-Pile Design Criteria - Odor Control System
Boring B-3A OCS & OCEP-1 (2021)
D Description C K E
s50
e
0-5 CLAY Neglect
5-8 CLAY 400 -- 115 30 0.020
8-10.5 CLAY 125 -- 115 30 0.020
10.5-13 SAND -- 28 50 20 --
13-17 CLAY 250 -- 55 30 0.020
17-27 SAND -- 29 50 20 --
27-32 SAND -- 36 55 60 --
32-37 CLAY 1,500 500 0.007
37-45 SAND -- 29 50 20 --
Where: D = depth (ft) C = shear strength, psf (undrained)
= angle of internal friction, deg. = effective unit weight, pcf
e
K= modulus of subgrade reaction (pci) E= 50% strain value
s 50
K and E were obtained from published correlations.
s50
Structural Floor Slabs
Suspended structural floor slabs must be used in conjunction with the drilled pier
foundations. The structural slabs shall have a minimum 6-inch void space below the bottom
of the structural slabs and grade beams spanning between the piers. Soil retainers shall be
used to ensure that the void space is maintained after construction is completed. All beams
spanning between piers shall be structurally connected to the piers.
7 of 8
March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E.402 W Broadway Street,Corpus Christi, Texas
RETL JobNumber G121393SA1MSA No. 3399, Project No. 18084A, Task Order No. 15
Cartonforms may be utilized to create the minimum 6-inch void space, or a crawl space can
be constructed. A crawl space will allow for hanging of underfloor utilities such that
differential movements between the underfloor soils and the relatively fixed floor slabs, and
the associated differential movementsbetween buried underfloor utilities and the structures,
should not pose potential future issues at utility penetrations. In addition, a crawl space will
allow for future maintenance beneath the structures, if necessary. If a crawl space is
utilized, a mud slabshould be used in the underfloor area and provisions should be made to
remove any water that enters the crawl space and not allow water to accumulate.
Closing
The additional deep foundationdesign recommendations provided in this Geotechnical
SupplementNo. 1 are intended to complementour original report and recommendations
contained in that report.Any information, discussion and recommendations provided in our
original report and not specificallyamendedor addressed in this Geotechnical Supplement
No. 1 shall remain valid and unchanged from the original report.
Often,because of design and construction details that occur on a project, questions arise
concerning soil conditions, and Rock Engineering and Testing Laboratory, Inc. (RETL),
Texas Professional Engineering Firm No. –2101, would be pleased to continue its roleas
Geotechnical Engineer during the project implementation.
RETL also has great interest in providing materials testing and observation services during
the construction phase of thisproject. Ifyou will advise us of the appropriate time to discuss
these engineering services, we will be pleased to meet with you at your convenience. If you
have any questions, or if we can be of further assistance, please contact us at (361) 883-
4555.
Sincerely,
James P. Bauer, P.E.Francisco J. Arias, P.E.
Corpus ChristiBranch ManagerSenior Geotechnical Engineer
Attachments:
Boring location Plan
Boring LogsB-1A EET, B-2 SEP, and B-3 OCS
Key to Soil Classificationand Symbols
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GEOTECHNICAL ENGINEERING
CONSTRUCTION MATERIALS
ENGINEERING & TESTING
SOILS ASPHALT CONCRETE
BORING LOCATION PLAN
Legend:
Boringdrilled in 2008
Borings drilled in 2021
New borings drilled in 2022
B-1A EET
B-2A SEP
B-3A OCS
March 22, 2022 BROADWAY WWTP REHABILITATION (18084A)
Attn: Ms. Sandra L. Gomez, P.E.402 W Broadway Street,Corpus Christi, Texas
RETL Job Number G121393SA1MSA No. 3399, Project No. 18084A, TaskOrder No. 15
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